Roof panel standing seam assemblies

ABSTRACT

A standing seam roof assembly in which adjacent roof panels are supported by underlying support structure in overlapping edge relationship to form a standing seam between adjacent roof panels is disclosed. A first roof panel having a female sidelap portion forms a male insertion cavity and a second roof panel having a male sidelap portion is inserted into the male insertion cavity to form the standing seam assembly. The standing seam assembly prevents unfurling of the first and second roof panels by forming force couples that resist forces due to uplift of the first and second panels. A mastic material is compressed between portions of the female and male sidelap portions, thereby forming a weathertight seal.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of the following U.S.patent applications and incorporates by reference each of theapplications:

FREE ROOF ASSEMBLY, Ser. No. 185,480, filed Jan. 21, 1994, now pending,and

FREE ROOF ASSEMBLY FOR REROOFING A BUILDING STRUCTURE, Ser. No. 181,756,filed Jan. 21, 1994, now pending, which applications are continuationsof the following:

STANDING SEAM ROOF ASSEMBLY AND SUPPORT APPARATUS, Ser. No. 846,278,filed Mar. 2, 1992, now U.S. Pat. No. 5,303,528, which is a Division ofthe following:

STANDING SEAM ROOF ASSEMBLY AND SUPPORT APPARATUS, Ser. No. 402,901,filed Sep. 1, 1989, now U.S. Pat. No. 5,142,838, which is a Division ofthe following U.S. patent application:

STANDING SEAM ROOF ASSEMBLY AND SUPPORT, Ser. No. 745,320, filed Jun.14, 1985, abandoned, which is a continuation-in-part of the following:

STANDING SEAM ROOF ASSEMBLY, Ser. No. 568,083, filed Jan. 4, 1984, nowU.S. Pat. No. 4,597,234; and a continuation of the following:

ROOF ASSEMBLY FOR REROOFING A BUILDING STRUCTURE, Ser. No. 604,884,filed Oct. 26, 1990, abandoned, which is a Division of:

FREE ROOF ASSEMBLY FOR REROOFING A BUILDING STRUCTURE, Ser. No. 136,246,filed Dec. 18, 1987, abandoned, which is a continuation-in-part of thefollowing:

APPARATUS FOR SECURING A ROOFING SUPPORT SPACER TO UNDERLYING SUPPORTSTRUCTURES, Ser. No. 090,689, filed Aug. 28, 1987, abandoned, which is aContinuation-in-part of the following:

STANDING SEAM ROOF ASSEMBLY AND SUPPORT, Ser. No. 745,320, filed Jun.14, 1985, abandoned, which is a continuation-in-part of the following:

STANDING SEAM ROOF ASSEMBLY, Ser. No. 568,083, now U.S. Pat. No.4,597,234.

OTHER RELATED APPLICATIONS

The present application is related to the following simultaneously filedpatent applications, each of which is incorporated herein by reference:

ROOF SPACER APPARATUS, filed Jun. 7, 1995

ROOF SUPPORT APPARATUS, filed Jun. 7, 1995

ROOF FRAMING SYSTEM, filed Jun. 7, 1995

APPARATUS FOR ROOF SUPPORT, filed Jun. 7, 1995

STANDING SEAM ASSEMBLY RETENTION APPARATUS, filed Jun. 7, 1995

ROOF PANELS WITH STIFFENED ENDLAPS, filed Jun. 7, 1995

CLAMPING APPARATUS FOR STANDING SEAM ASSEMBLIES, filed Jun. 7, 1995

ROOF PANEL SYSTEMS, filed Jun. 7, 1995

STANDING SEAM ASSEMBLY, filed Jun. 7, 1995

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a roof assembly for a buildingstructure, and more particularly, but not by way of limitation, tostanding seam roof systems.

2. Discussion of Prior Art

Numerous types of roof assemblies have previously been proposed forpre-engineered buildings in efforts to provide a watertight roofassembly, while at the same time enabling the roof assembly to expandand contract as changes in temperature are encountered. Typical of suchprior art roof assemblies of considerable success in recent years is thestanding seam roof assembly. The panel members of the standing seam roofassembly are joined along lapped together side edges forming thestanding seams. The panel members of the standing seam roof are securedto the secondary structural members by either clips or throughfasteners. Clips can be of two types: floating (one or two piecemoveable); or fixed (one piece with no movement allowed between thepanel and its supporting structure). Through fasteners attach the panelsto underlying support structure and substantially fix or lock the panelsand support structure together so that no differential movement canoccur.

Roofs may be classified as shed roofs and low slope gasket roofs. Shedroofs are roofs that shed water because gravity pulls the water down andaway from panel joints more effectively than wind or capillary actionpropel water through the joint. Shed roofs generally occur over slopesof three to twelve or greater. Low slope gasket roofs, on the otherhand, provide roof joints that are made watertight by placing a gasketmaterial between the panel joints and securing the gasket in place by,for example, encapsulating the gasket material or exerting pressure uponit. Generally, low slope gasket roofs are usually 1/4 to twelve slope orgreater.

Heretofore, field seamed gasket joints have been limited to using twopiece clips wherein movement between the roof and its underlyingstructure took place within the clip. The reason for this is that in thepast the line of sealant serving as a gasket and the top hook portion ofthe clip intersected and if the clip moved in relation to the panelwhich held the sealant, the relative movement deformed and destroyed thegasket seal. One piece clips have been used freely in shed roofs where agasket seal was not required.

Standing seam metal roofs exhibit considerable diaphragm strength and itis desirable to use this strength by interconnecting the roof to itssupport frame to help stabilize the support frame, rather than to braceand stabilize the support frame by other means.

Past practices have been to stabilize the support frame by means ofseparate bracing and on gasket roofs to use a suitable two piecefloating (moveable) clip to allow the brace and frame to remain fixedand for the panel to move in relation to the frame as it is subjected totemperature change or other forces, or to limit the length of the panelrun to about 40 feet so that the movement of the panel as it expands andcontracts is low and does not materially damage its connection to theunderlying structure.

However, the desirable result of eliminating detrimental differentialmovement between the panel and its support structure on large roofs mayalso be achieved by constructing the underlying support so that it movesslightly to accommodate the movement of the roof as it is beingsubjected to movement because of temperature change or other forces.This means of construction is exemplified in a system produced by ReRoofAmerica.SM., Inc., referred to as the Flex Frame™ support system.

The interconnection of the panel members of the standing seam roof lendstiffness and strength to a flexible roof structure while allowing theroof structure to expand and contract as a function of the coefficientof expansion of the panel material and the temperature cycles of theroof panels.

If one of the means of using floating clips or if using a fixedconnection between the panal and the flexible framing is not used, therepeated action of expansion and contraction of the panel members tendsto weaken the panel-to-panel lap joints and the panel to framingconnection and thus often causes panel separation, structural failureand roof leakage. Leaks are generally caused by the weakening of thefastening members and working or kneading of the sealant disposed at thejoints. Prior art sealant for such roof assemblies required adhesion,flexibility and water repellency. Further, in many instances thepressure on the sealant varied greatly throughout the length of thesidelap and end lap joints of the panels, resulting in unevendistribution and voids of the joint sealant.

Many of the problems discussed hereinabove encountered in prior artstanding seam roofs, such as structural failures and leaks, have beenovercome by a standing seam floating roof assembly such as is disclosedin copending U.S. patent application Ser. No. 568,083, filed Jan. 4,1984 by Harold G. Simpson. The standing seam floating roof assembly isformed of elongated metal panels, each of which is provided with afemale member formed along one longitudinal edge and a male memberformed along the opposed longitudinal edge, adjacently disposed panelsbeing joined by interlocking female and male members thereof to form thestanding seam joint. Clips interconnect the standing seam joints and theunderlying secondary structure, with the upper portions of the clipshooking over the male members of the panels. Most such clips are of thesliding type which permits the hooking portion to move relative to asupporting base portion connected to the secondary structure, whilerelative motion between the clip hook and the metal panel issubstantially prevented. A sealant material is disposed to form amoisture dam in the interlocking joint of the female and male members.

Panel members of pre-engineered roof systems are constructed ofidentical sheet metal panels that are laid end to end, as well as sideby side as discussed above. Typically, these sheet metal panels areformed by either a factory or field roll forming process and are joinedside to side in the field by means of engaging (locking) a male with afemale sidelap using a process wherein the male and female, as they areinterlocked, deform within their elastic range. Alternatively, a fieldroll form seaming machine may be used that employs inelastic deformationto secure the male and female in interlocking engagement. Such end toend engagement presents the problem of sealing the end or butt joints,especially at the "four corner" areas where four of the panels areinterlapped to form a juncture area. Various butt joining techniqueshave evolved in the prior art, all of which involve selective notchingand overlapping to achieve a close fitting juncture area, and liberalapplication of mastic to effect the best seal possible under the designcircumstances. Serious deficiencies have been encountered in prior artlap joints, including water leaks, high costs, tooling complications,packaging, etc.

In addition to the use of standing seam roof assemblies on newlyconstructed pre-engineered buildings, standing seam roof assemblies arealso finding increasing usage in another segment of the roofingindustry, that of "built-up roof" replacement. Generally, a built-uproof is formed of a plurality of sections which are interconnected andovercoated with asphaltic composition to provide a watertight seal.While such substantially horizontal roof assemblies have generallyserved successfully, problems have nevertheless been encountered as abuilt-up roof ages, or when the building settles, or when constructionerrors result in water standing in pockets on the roof assembly. Thisstanding water often results in deterioration of the roof, causing leaksand the like to occur.

A need has long been recognized for a means for replacing a built-uproof, as well as other conventional roofs, which does not requiresubstantial modification to the preexisting roof and which is economicalboth in fabrication and on-site construction. Further, it is highlydesirable that the new roof assembly be capable of providing a new roofsurface independent to the variations in the surface of the preexistingroof assembly. Past repair methods, especially those capable of alteringthe slope of the roof surface to improve drainage characteristics, haverequired substantial destruction of the original roof assembly andextensive custom construction, thus exposing the building and itscontents to damage by the elements during the reroofing process andbeing excessively time consuming.

SUMMARY OF THE INVENTION

The present invention provides a standing seam roof assembly in whichadjacent roof panels are supported by underlying support structure inoverlapping edge relationship to form a standing seam between adjacentroof panels. The assembly comprises a a first roof panel having a femalesidelap portion that forms a male insertion cavity and a second roofpanel having a male sidelap portion that forms a standing seam assembly,wherein the male sidelap portion means is inserted into the maleinsertion cavity to form the standing seam assembly. The standing seamassembly prevents unfurling of the first and second roof panels byforming force couples that resist forces due to uplift of the first andsecond panels.

The preferred embodiment of the invention includes the use of a masticmaterial that is compressed between portions of the female and malesidelap portions, thereby forming a weathertight seal.

The female and male sidelap portions are interlockingly formed into thestanding seam assembly by insertion of the male sidelap portion into themale insertion cavity and a portion of the female sidelap portion iseither locked into place by way of elastic deformation, or field rollforming using a convention field roll forming seaming machine is used toconform the female sidelap portion to the required configuration for thestanding seam.

Accordingly, an object of the present invention is to provide a standingseam roof assembly for adjacent panels of a standing seam metal roofthat provides resistance to unfurling and unzipping of the seam due tothe exertion of environmental forces upon the roof panels that cause anuplifting force upon the panels.

Another object of the present invention is to provide a standing seamroof assembly with a configuration that resists unfurling and unzippingby producing force couples within the seam that resist the upliftingforces applied to the panels as a result of environmental forces.

Yet another object of the present invention is to provide a standingseam roof assembly that provides a weathertight seal.

Still yet another object of the present invention is to provide astanding seam roof assembly that is aesthetically pleasing and does notprovide the use of external fasteners while providing resistance tounfurling and unzipping comparable to that provided by the use ofexternal fasteners.

Other objects, features and advantages of the present invention willbecome apparent from the following detailed description when read inconjunction with the drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial view in isometric of a roof system of the typeserved by the teachings of the present invention.

FIG. 2 is a perspective partial cross-sectional view of a roof system ofFIG. 1.

FIG. 3A is an elevational front view of a roof support system shown inFIG. 2. FIG. 3B is an elevational side view of the roof support systemof FIG. 3A.

FIG. 4 is an elevational view of a sidelap clip member utilized in aroof system of FIG. 1. FIG. 4A is an enlarged view of the hook portionof the sidelap clip member. FIG. 4B is a partial top plan view of thehook portion of FIG. 4. FIGS. 4C and 4D show another embodiment of thesidelap clip member. FIG. 4E provides a force diagram for the forcesexerted upon the sidelap clip member when subjected to uplift loads.

FIG. 5 is an end schematic view of the profile of a roof panel memberwhich can be utilized in the roof system of FIG. 1.

FIG. 6 is a partial side elevational view of an alternate attachingassembly for the roof panel member of FIG. 5. FIG. 6A is a view taken at6A--6A in FIG. 6.

FIG. 7 is a partial side elevational view of yet another alternateattaching assembly for the roof panel member of FIG. 5. FIG. 7A is aview taken at 7A--7A in FIG. 7.

FIGS. 8 and 8A are side and elevational views, respectively, of asidelap clip member which incorporates an insulation cutting feature.

FIG. 9 is one other attaching assembly for a modified roof panel memberwhich is shown in schematic profile in FIG. 9A. FIG. 9B is a forcediagram at one of the hooking clip members.

FIG. 10 is a partial side elevational view of another alternateattaching assembly for the modified roof panel member of FIG. 9A. FIG.10A is a view taken at 10A--10A of FIG. 10.

FIG. 10B is a side view of the panel and the elongated panel clipattached to the support structure.

FIG. 11 is partial plan view of a roof panel member usable in the roofsystem of FIG. 1.

FIG. 12 is a partial plan view of a roof panel member usable in the roofsystem of FIG. 1, showing the position of a portion of the endlapsealant.

FIG. 13 is an elevational view of the profile of the standing seam jointformed by interlocked adjacent roof panel members of the type shown inFIG. 11.

FIG. 14 shows an alternate sidelap sealant for use in the standing seamjoint of FIG. 13.

FIGS. 15A through 15C are partial plan views of the interlapped panelcorners depicting progression through assembly of the roof panel memberof FIG. 11 at the four corner juncture area.

FIG. 15D is an elevational view in partial cutaway detail of the fourcorner juncture area depicting interlapped panel ends prior toinstallation of cinch strap and backup plate assemblies. FIG. 15E is aview taken at 15E--15E in FIG. 15D, and FIG. 15F is a view taken at15F--15F therein.

FIG. 15G is a partial detailed, elevational side view of corner A of theroof panel member of FIG. 11. FIG. 15GG is a view taken at 15GG--15GG inFIG. 15G.

FIG. 15H is a similar view of corner B of the FIG. 11 roof panel member.

FIG. 15I is a partial detailed, elevational side view of corner C of theFIG. 11 roof panel member. FIG. 15II is a view taken at 15II--15II inFIG. 15I.

FIG. 15J is a partial detailed, elevational end view of corner D of theFIG. 11 roof panel member.

FIGS. 16A through 16F are similar to corresponding views in FIGS.15A-15F above but show the installation sequence of the roof panelmembers as used on an oppositely sloped roof structure.

FIG. 17 is an elevational view of the bar strip portion of a cinch strapassembly used to sealingly interconnect interlapped panel ends at thefour corner juncture area. FIG. 18 is a top plan view of the backupplate portion of the cinch strap assembly.

FIG. 18 is a plan view of a companion backup plate to the roof panelmember shown in FIG. 11. FIG. 18A provides an alternative backupassembly to be used in lieu of the backup plate of FIG. 18. FIG. 18Bprovides an enlarged partial cross-sectional view of FIG. 18A.

FIG. 19 is a plan view of a stirrup connector.

FIG. 19A is an are elevational views of a stirrup connector.

FIG. 19B is another elevational view of a stirrup connector.

FIG. 20 is an elevational view of the backup panel of FIG. 18.

FIG. 21 is an elevational view of the seam roller.

FIG. 21A is an elevational view of the seam roller before locking theroof panels together.

FIG. 21B is an elevational view of the seam roller after locking theroof panels together.

FIG. 22 is another elevational view of the seam roller.

FIG. 22A is another elevational view of the seam roller before lockingthe roof panels together.

FIG. 22B is another elevational view of the seam roller after lockingthe roof panels together.

FIG. 23 is an elevational view of the sidelap of the present invention.

FIG. 24 is an elevational view of the standing seam assembly.

FIG. 25 is a view of the standing seam assembly including a fastenerconstructed in accordance with the present invention.

FIG. 26 is an elevational view of the standing seam assembly before thefield roll forming process.

FIG. 27 is an enlargement of the horizontal clip.

FIG. 28 is an enlargement of the horizontal clip.

FIG. 29 is a view taken along the 29--29 line.

FIG. 30 is an elevational view of the formed seam.

FIG. 31 is an enlargement of the formed seam.

FIG. 31A is an enlargement of the seat portion of the formed seam ofFIG. 31.

FIG. 32 is a side view of another field roll formed standing seamassembly.

FIG. 33 is an elevational view of the standing seam assembly.

FIG. 34 is an expanded view of the standing seam assembly.

FIG. 35 is a plan view of the horizontal clip having rectangular shape.

FIG. 36 is an elevational view of the standing seam assembly with anexternal clip.

FIG. 37 is an isometric view of the external clip.

FIG. 38 is an elevational view of the standing sidelap seam assembly.

FIG. 39 is a view of the standing seam sidelap assembly after completionof the field rolling process.

FIG. 40 is an alternate view of the standing seam assembly of FIG. 39.

FIG. 41 is an elevational view of the standing seam assembly withadjacent roof panels.

FIG. 42 is an enlarged view of a horizontal clip.

FIG. 43 is an elevational view of a horizontal clip.

FIG. 44 is another enlarged view of a horizontal clip.

FIG. 45 is a perspective view of the clip base.

FIG. 45A is an enlarged view of the base of the hold down clip on FIG.45.

FIG. 45B is an enlarged view of a two-piece hold down clip assembly.

FIG. 46 is an elevational view of a standing seam assembly.

FIG. 47 is an elevational view of a clamping tool.

FIG. 48 is a plan view of clamping jaws.

DESCRIPTION

Standing seam metal panel roof systems of the functional gasket type areusually placed on relatively flat building slopes and as a result mustbe capable of resisting a standing head of water. Because such roofs arerelatively flat, panel runs are often long and expansion and contractionjoints are difficult to make watertight. Thus, panel attachment to theunderlying secondary structural system must accommodate panel expansionand contraction. Steeper roof pitches, used with architectural panels,are shorter and require less end lap, sidelap and fastenerwatertightness.

To obtain watertightness at points of attachment of the roof panels tounderlying structure, panels must be permitted to expand and contract inrelation to the underlying structure or the panels and the underlyingstructure must be permitted to move in unison without unduly strainingor fracturing the panel. This may be accomplished by limiting the lengthof the panels or by utilizing support structures sufficiently flexibleto allow the attachment means to move with the expanding or contractingpanel. The flexibility of the support structurals must be greater forlonger panel runs because, other factors being equal, the expansion orcontraction of the panels will be greater.

Past practice has been to attach the center and sidelap joints witheither penetrating or non-penetrating fasteners. For non-penetratingclips, past clip practice has been to use either a fixed or sliding clipwith a minimum length contact surface between the hold-down portion ofthe clip and the top of the male leg of the seam. The length of the cliphas been held to a minimum, resulting in stress concentrations in thepanel at the point of attachment, leading to severe distortion in thepanel joints as the panels are subjected to wind uplift.

The standing seam clip bears only on the male seam portion of the panelinserted into the adjacent female seam portion. The female seam portionis not retained directly by the clip and as a result the load from thefemale seam portion must pass through the male seam portion and theninto the clip where it can in turn pass to the secondary structural.This action tends to "unravel" the panel joint and allow distortionsover the short section retained by the clip. This has resulted inpremature panel failure when subjecting such panels to wind uplift.

A roof panel is usually attached to underlying supporting structure in amanner that causes the panel to act as a continuous beam. Thisarrangement substantially reduces the maximum moment occurring at anyone point compared to the moment that would occur in a simple beam,other factors being equal. However, this means of construction causes anegative moment to occur at the attachment point. This negative momentpeaks and drops off very quickly as the panel section underconsideration moves from the center line of the attaching clip towardsthe point of inflection (P.I.), the P.I. being that point where themoment in the panel changes from positive to negative.

Past center hold-down practice has been to coordinate such usage withedge hold-down practice so that if through fasteners were used to attachthe center of the panel to the underlying structural, then fixed clipsor through fasteners were used to attach the edge of the panel to theunderlying structural; and conversely, if the panel edge attachmentconsisted of a floating, (two-piece, moveable) non-penetratingattachment means, such as a clip, then the center hold-down was eithertotally eliminated or a floating, non-penetrating center hold-downdevice was utilized. However, past non-penetrating center hold devicesheretofore have largely been ineffective and expensive.

The effectiveness of non-penetrating center hold-down devices isinfluenced by the number and height of corrugations formed in the paneland the width, thickness and strength of the metal laterally separatingthe corrugations. The configuration and number of panel corrugations inturn has a direct impact on the efficiency of material utilization,which in turn is a primary cost factor. Conventional standing seam roofsmay only achieve a flat-width-to-coverage ratio as low as 1.25:1 wherethrough fasteners exist only at panel end laps and do not occur at thepanel centers. On the other hand, non-standing seam panels with centerhold-down fasteners are commonly 36" wide and may achieveflat-width-to-coverage ratios as low as 1.17:1.

In summary, it is clear that panels with through fasteners, while havingmany disadvantages associated with the placement of fasteners throughthe panel, can achieve better material utilization and erectionefficiency than can standing seam panels that utilize onlynon-penetrating fasteners. The primary reason for this is that the panelconnector can be placed immediately adjacent to intermediatecorrugations which greatly increases wind uplift resistance.

Thus, a panel design that can achieve the material utilization anderection efficiency of a panel having through center fasteners, withoutthe disadvantages of structurally compromising the structuralconnections to underlying secondary support members, or a panel withsimple non-penetrating center hold-down fasteners, would providesignificant advantages over prior art panels. Disclosed herein is animproved panel design with a secondary support system having sufficientflexibility such that the panels and fasteners under the influence ofexpansion and contraction move the underlying structurals while stillmaintaining the structural integrity and watertightness of the overallsystem. Taught herein is an alternative approach to achieve thisdesirable effect by coordinating the shape, spacing and size of theintermediate corrugations and the standing seam sidelap corrugations sothat panel fasteners capable of moving in relation to the panels isachieved, while at the same time minimizing the flat width to corrugatedwidth coverage ratio.

The panel design provided herein serves to minimize panel materialthickness. It is of no benefit to minimize the panel flat width tocorrugated width ratio if accomplished at the expense of other benefitssuch as increasing the base material thickness. To the contrary, it isvery desirable to also reduce the panel thickness to minimize the amountof material in each panel. Of course, these goals could be achieved byreducing the span between secondary support members, but this would leadto increased costs in other elements of the building structure.

FIGS. 1-4

Referring now to the drawings, and more particularly to FIG. 1, showntherein is a portion of a roof system 10 supported by a preexisting roof12 of a building structure 14. The preexisting roof 12 of the buildingstructure 14 can be any preexisting roof structure, such as a built-uproof, which is connected to and supported by conventional elements, suchas a primary and secondary structural systems (not shown), and aplurality of wall members 18 (one shown). The primary structural systemof a building structure will usually consist of a plurality of upwardlyextending column members which are rigidly connected to a foundation anda plurality of primary beams which are generally horizontally disposedand supported by column members. The secondary structural system willusually consist of a number of purlin or joist members supported by thecolumn members or other members, such as primary beams.

The roof system 10 is formed of a plurality of overlapping roof panels24 interconnected to provide a roof plane for the roof system 10, andwhile generally flat panels (except for joints and stiffener ribs) aredepicted, it will be understood that the present invention is alsoapplicable to curvilinearly shaped panels sometimes preferred by certainarchitectural planners. Further, if desired, the roof sections of theroof system 10 can be disposed on the preexisting roof 12 such thatinterlocking adjacent roof sections form a multi-pitched roof. On theother hand, the roof sections can be joined such that the roof system 10is provided with a substantially single roof plane having aunidirectional slope, as depicted in FIG. 1.

The roof panels 24 of the roof system 10 are supported by a plurality ofadjustable roofing support spacers 26 of the type disclosed in copendingpatent application entitled ROOF SPACER APPARATUS, Ser. No. 08/486,950,filed Jun. 7, 1995, incorporated herein by reference. Each of theadjustable roofing support spacers 26 extends upwardly from thepreexisting roof 12 as required to support the roof panels 24 in apredetermined planar slope. Each adjustable roofing support spacer 26 ischaracterized as having one or more base support members 28, a spatiallydisposed upper beam 30 and an adjustable web assembly 32 interconnectingthe base support members 28 and the upper beam 30 such over all assemblybeing adjustable. The base support members 28 provide for loaddistribution across the area of the base support members 28 onto thepreexisting roof 12. The web assembly 32 of each of the adjustableroofing support spacers 26 is connected to the upper beam 30 and thebase support members 28 at various positions so that the upper beam 30of each of the adjustable roofing support spacers 26 is disposed aselected height above the base support members 28 (and thus above anupper surface 22 of the preexisting roof 12) independent of slope orirregularities that may be present in the preexisting roof 12.

The present invention presents a novel panel profile, and it will beclear that the adjustable roofing support spacers 26 are useable withother panel and insulation designs. While the panels of the presentinvention can be attached directly to the upper beams 30 as shown inFIG. 1, the panels can be supported in a number of ways, one of which isdepicted in FIG. 2; described hereinbelow.

Roof panels 120, having the profile taught in U.S. Pat. No. 4,597,234and referenced hereinabove, are supported on support assemblies 122which are attached to the upper beam 30 of the adjustable roofingsupport spacers 26. The roof panels 120, only portions of which areshown, are depicted as being standing seam panels, with theirinterlocking edge seams being supported by clip portions of the panelsupport assemblies 122, as will become clear below.

A conventional, standing seam roof panel, on the average, is about 35long and about 16 to 24 inches wide, although other lengths and widthsare known. Typically, a standing seam roof panel member is made of24-gauge sheet metal material, and because of this relative thin metal,corrugations are commonly formed running lengthwise in the panel toprovide sufficient strength for load bearing. Further, typical prior artstanding seam roof panels are secured at the interlocking sidelap jointsand at the end overlap of contiguous panels.

Fastener penetration of the panels, except at the end overlaps, isgenerally avoided in large roofs having relatively fixed support systemsin order to minimize leakage points. The reason for this is that withthe connection of the panels directly to relatively rigid underlyingstructural members, thermal expansion has caused the panels to rip outaround the fasteners. When used on short spans, or flexible secondarystructural members, this usually does not occur, and the advantages ofthrough center fasteners and an unsupported standing seam joint can beused advantageously. The medial portions of the panels located betweenstanding seam joints are not normally secured to the underlyingstructural members. Such roof panels are inherently laterally flexiblebut longitudinally inflexible. Because the panels are usually disposedto extend transverse to the roof, if the panels are joined rigidly endto end and attached rigidly to underlying secondary structures andportions of the underlying structures are rigid, much damage can becaused by differential movement between the two.

The panel width and material thickness are dictated by the structuralconfiguration of the panel and its support structure, as well as theinwardly and outwardly directed load requirements imposed by regulatory,insurance and good engineering practices. Other factors being equal, thematerial thickness that is required is normally greater for outwardlydirected load than for inwardly directed load. The reason is that thepanel is more fully supported by the underlying secondary supports forinwardly directed load than for outwardly directed load. The supportpoints, other than at panel ends, for outwardly directed load were inthe past located only at points of attachment of the panel of thesecondary structural. Past practices limited these points of attachmentto places such as those where the panel edge points pass over secondarystructural members and where attachment could be made without causingadditional holes in the panel.

Several attempts have been made to devise intermediate corrugation andcorresponding clips to hold the center of the panel to the underlyingstructural. Such attempts have had limited success because the outwardlydirected force bows the center of the panel outward as load is appliedand causes the clip to become disengaged. As will be discussed morefully below, the present invention provides for attachment of medialpanel portions to underlying structural members when subjected to upliftloads, while maintaining equivalent panel quality, of using thinnergauge material and wider panels while at the same time eliminatingripping of the panel around fasteners so as to reduce roof leakpotential and the adverse effects of differential expansion andcontractions. This presents considerable benefit in time and costsavings to the pre-engineered building art.

Continuing this discussion with reference to FIG. 2, a flexible membrane124 is extended substantially tautly over an appropriate structuralsupport member such as a box joist beneath the panel support assemblies122 and secured thereby to the upper beams 30. A layer of compressibleinsulation, such as insulation 60, is supported by the flexible membrane124 such as a built up roof membrane beneath the roof panels 120 insubstantially its pre-installed state. As for the type of blanketinsulation 60 to be used, it will be noted that such insulation isusually a laminated product that comprises a layer of compressiblemineral insulation or chopped glass fiber insulation which is bonded viaan adhesive to a flexible facing membrane. However, other types ofinsulation, such as blown shredded paper, glass fibers and foam, may beused advantageously. The flexible membrane 124 may consist of one ormore thin layers of materials such as aluminum foil or vinyl plasticwhich serves to provide a vapor barrier for the building envelope. Atypical blanket batt insulation is made by the Mizell Brothers Companyof Dallas, Tex., which is a product comprising a laminated facingmembrane made of a layer of vinyl, a layer of fiberglass scrim, and alayer of aluminum foil. Bonded to the facing membrane is a thick layerof compressible fiberglass material.

The flexible membrane 124 may also be a separate, independent structuralmember which provides a continuous membrane vapor barrier and alsoserves as a support platform for the insulation layer 60. An independentmembrane preferably will be a steel or aluminum sheet or a facingflexible facing membrane about one to two mils in thickness with anembedded scrim, such as Fiberglass or nylon, capable of taking tensileload. The flexible membrane 124, if separate to the insulation, isplaced over the upper beams 30 by attaching it between convenientsupport members, such as a building wall or roof structurals, so thatthe membrane extends substantially taut therebetween. Once the membraneis tautly in position, the insulation 60 is simply placed upon themembrane.

Of course, the positioning of the membrane 124 and insulation 60 overthe upper beams 30 is intended as an optional treatment to the provisionof a similar membrane and insulation directly upon the preexisting roof12 as discussed above with reference to FIG. 1. Further, there will mostlikely be applications where both insulations are installed, or in whichthe insulation and/or membrane can be eliminated altogether.

The panel support assembly 122 shown in FIG. 2 comprises a plurality ofbase clips 126 each of which has a median web portion 128. At the lowerend of the median web portion 128 there is formed a leg portion 130through which self-drilling/self-tapping screws 132 extend to secure thebase clip 126 to the underlying support spacers 26. As shown in FIG. 3A,the attachment of the base clips 126 serve to secure the flexiblemembrane 124 to the top of the upper support spacers.

The panel support assembly 122 also comprises a plurality of panelsupport beams 134 that are generally elongated channel shaped membersarranged in overlapping, end-to-end relationship. As shown, the panelsupport beams 134 extend generally parallel to the underlying upperbeams 30, but where desired, the panel support beams can be disposed torun perpendicularly to, or otherwise angularly to, the underlying upperbeams 30. Preferably, the base clip 126 is formed as an integral portionof the panel support beam 134 to which it is attached. That is, each ofthe base clips 126 is formed as an extension of the web portion of itschannel shaped panel support beam 134 and is press formed to extenddownwardly therefrom to support one end of its respective panel supportbeam 134 at a predetermined distance above the underlying upper beam 30.This is for the purpose of providing clearance below the panel supportbeam 134 in order to provide space for the insulation 60 to bepositioned thereunder, and further, each base clip 126 has thecapability to flex to accommodate expansion and contraction of the roofpanels 120.

The roof panels 120 are secured to the panel support beams 134 and reston, and are connected to, upper support surfaces 136 thereof whichprovide support for the medial portions of the roof panel 120 membersfor both inwardly and outwardly directed load. As shown in FIGS. 3A and3B (which show only the male sidelap joint of one roof panel 120 inorder to display the clip), an upwardly extensive clip member 138 issecured to the upper support surface 136 of the overlapped panel supportbeams 134 and panel support beams 134A via a screw 140. An upper hookportion 142 of the clip member 138 is formed to hook over the apexportion of the male sidelap joint of the roof panel 120.

Once the flexible membrane 124 is tautly secured to selected anchoringpoints and stretched over the support spacers 26, the base clips 126 aresecured in place via the screws 132, and the panel support beams 134 areoverlappingly aligned along each of the support spacers 26. The standingseam roof panels 120 are snapped into overlapping and interlockingrelationship over the clip member 138.

FIG. 4 shows an enlarged view of the clip member 138 which has anupwardly extending web portion 144 which supports the hook portion 142and a laterally extending male joint support shelf 146. The supportshelf 146, which has a downwardly turned lip portion 148 for strength,is disposed to extend beneath the male joint portion of the roof panel120 as shown in FIG. 3B. This feature of the clip member 138 is a uniquefeature of present invention in that support of the male edge portionassists in increasing joint sealing integrity as the snap on female edgeportion of the contiguous roof panel is laid in place and interlocked tothe male edge portion. Another unique and advantageous feature of theclip member 138, as shown in FIG. 3B, is that the screw 140 connectingthe clip member 138 to its underlying support structure is located closeto the web.

A force diagram that results from the clip's resistance to wind uplifton the panel is shown in FIG. 4E. Placing the fastener close to thecenterline of the clip hook (resultant P1) and at a distance from afulcrum (force P3 at the toe of the clip) about which the base of theclip rotates as upward load is applied, reduces the prying action on theclip base, thus reducing the bending load in the clip base and the pullout force exerted on the fastener located at force line P2.

If the distance L1 equals L2, then force P2 is twice the uplift load P1.If L1 equals 1/4 L2, then P2 is only 11/4 times P1. This is a verysignificant reduction in the load on the fastener and bending in thebase thus allowing a more efficient clip base plate and smaller fastenerto be used.

Other features of the clip member 138 include a provision of embossedstrengthening ribs 150 in a base leg portion 151. Further, the base legportion 151 is provided with downwardly extending cleat members 152 fromits under surface 154 that serve to dig into the upper surface of thepanel support beam 134 to assist in seating the base leg portion 151 andprevent its rotation with the torquing of the screw 140. This latterfeature assures that the hook portion 142 is maintained in properalignment on the upper part of the male joint being pinned thereby.Finally, the outer surfaces of the clip member 138 are selectivelytreated with a lubricant or friction reducing coating 156 as depicted inFIG. 4A which is a further enlargement of the hook portion 142. Thecoating 156 is also provided on the support shelf 146, another bearingsurface area of the clip member 138. The purpose of the coating 156 isto reduce frictional contrast between the stationary clip members 138and the supported roof panels 120 during expansion and contraction ofsame. Further, end edges 158 of the hook portion 142 are curved orrounded slightly, as depicted in the partial top plan view of FIG. 4B,and are made smooth so as to prevent the end edges 158 from digging intothe joint portions of the supported roof panel 120 during relativemovement thereof.

FIGS. 4C and 4D show another embodiment of clip member 138A. Portions ofthe clip member 138A are identical to corresponding portions in the clipmember 138 of FIGS. 4, 4A and 4B, and such portions bear identicalnumerical designations in FIGS. 4C and 4D, to wit, the hook portion 142,the strengthening ribs 150, the base leg portion 151, the cleat members152 and the lubricant coating 156. In the clip member 138A, the supportshelf is cut directly from web portion 144A and form bent along formintersection 146B to position support shelf 146A extending generallynormal to the web portion 144A. Lip portion 148A is angularly extensivefrom the distil edge of the support shelf 146A, and lower edge 148B ofthe lip portion 148A is caused to be supported by a pair of supportingear members 144B that are form bent portions of the web portion 144Athat (prior to form bending) extend into profiled hole 149 left in theweb portion 144A once the support shelf and lip portion are broached andform bent as described. Because of the weakening of the web portion 144Aby the profiled hole 149 therein, it is desirable to provide a pair ofembossed strengthening ribs 150A in the web. The thus described clipmember 138A provides an exceptionally stable yet inexpensive clipcomplement for the roof system 10.

FIGS. 5-10

The present invention provides a number of improvement features for theroof system 10 of FIG. 1, many of which are applicable to variousroofing panel profiles such as those shown in the drawings discussedhereinabove. The invention shown in FIGS. 5 through 10A is a new andunique panel incorporating features which enables one to manufacture anduse a wider, light gauge, more water tight and more wind resistantstanding seam metal panel than heretofore possible. This is accomplishedby incorporating edge standing seam corrugations, an optional number ofcenter panel ribbed corrugations and an optional center panel hold-downassembly that allows the panel to perform exceptionally well for aspecific range of end use applications. More particularly, disclosedherein are two alternative methods of achieving a panel and panelsupport system that achieve, through either the use of through fastenersor clips, adequate structural stability and at the same timeaccommodating panel expansion and contraction without roof performancebeing adversely affected.

For such a wide panel to perform satisfactory it is necessary tosuitably stiffen the panel longitudinally and to connect the edge andcenter portion of the panel to the underlying structure. The connectionbest suited to connect the edge and center portion of the panel to theunderlying structure will depend on a number of factors relating to theoverall nature of the building, its supporting structure and theinsulation system used.

This unique metal standing seam roof panel system possesses superiormaterial utilization and erection economy. The flat width of 26 gage(0.019 inch) material utilized to roll form the panel may be as low as117% of the coverage of the panel after forming and being attached tothe roof while achieving the benefits of continued watertightness,superior wind uplift resistance and easy low-cost erection. The panelsidelap may incorporate any one of a number of sidelap configurations asdisclosed herein or as utilized in other designs.

Shown in FIG. 5 is an end schematic view of the profile of a roof panelmember 160 which incorporates the unique features just described. Itshould be noted that this discussion entails the use of several figuresets and the item numbers used in each figure set may only apply to theitems in that set.

In order to illustrate the profile geometry, the roof panel member 160is shown interlocked with a contiguous roof panel member 160A on oneside and with contiguous roof panel member 160B on the other sidethereof. The roof panel member 160 has a vertically extending malesidelap joint portion 162 formed along one side thereof, and avertically extending female sidelap joint portion 164 formed along theother side thereof. In like fashion, the roof panel member 160A hasvertically extending male and female sidelap joint portions formed alongits sides, with only a female sidelap joint portion 164A depicted inFIG. 5. Similarly, the roof panel member 160B has vertically extendingmale and female sidelap joint portions formed along its sides, with onlya male sidelap joint portion 162B being depicted in FIG. 5. In each ofthese roof panel members, the male sidelap joint portion is supported bythe underlying support structure and is lockingly receivable in theinsertion cavity formed by the snap together female sidelap jointportion of a contiguous panel. In FIG. 5, the male sidelap joint portion162 is interlocked with the female sidelap joint portion 164A. Also, themale sidelap joint portion 162B of the roof panel member 160B isinterlocked with the female sidelap joint portion 164 of the roof panelmember 160.

The roof panel member 160 has a number of parallel structuralcorrugation crowns (two of which are illustrated and numericallydesignated as 166 and 168) formed in the medial portion of the panel.The size, shape and number of the structural corrugation crowns 166 and168 are generally coordinated with the required geometry of the paneland the use condition. It will be readily understood that the structuralcorrugation crowns 166 and 168 are distinguishable from minor ribs whichare often employed to eliminate "oil canning" effects or rippling of thepanels. The structural corrugation crowns 166 and 168 will typicallyhave depths in excess of 1/2 inch and will be formed running the lengthof a roof panel in a conventional manner to add load bearing strength tolight gauge sheet metal. It will be noted that the roof panel 160 may beplaced directly on top of the insulation 60 and that attaching screws170 secure the panel directly to the underlying upper beam 30 of thesupport spacer 26. In the embodiment shown, three screws are employedand are inserted adjacent to the female sidelap and each of thestructural corrugation crowns 166 and 168 to provide adequate restraintto the corrugations which form spanning members between underlyingsupport structure. It being desirable for attaching screws 170 to belocated immediately adjacent the structural corrugation crowns 166 and168 and the female sidelap joint portion 164 to minimize deflection inroof panel member 160. It being understood additional screws and screwlocations may be utilized to minimize distortion. Furthermore, thestanding seam joint formed by the interlocking male/female sidelap jointportions 162B, 164 and 162, 164A are not secured via clip members as isconventional. Thus the roof panel member 160 and its attaching meansprovides a panel having the water tightness afforded by a snap togetherfield roll formed standing seam sidelap joint while having an unlimitedpanel width securable to the underlying support structure. Because ofthe vertically rising sidelap joint portions when the sidelap utilizes asnap together joint, the panels can be effectively snapped togetherwithout a seaming tool because backup support is accorded to the jointduring seaming connection by the supporting structure itself.Alternatively, the sidelap may be overlapped and then seamed with aseparate field seaming machine.

As shown in FIGS. 6 and 6A, the roof panel member 160 can alternately beattached to the underlying support spacer 26 by the placement of asemi-rigid foam spacer 172 over the insulation 60 with extended screws174 extending therethrough to attach the upper beam 30. The spacer 172may be provided with a more rigid upper surface via stiffener members176, optionally adhered to the spacer 172, to prevent fastenerindentation upon insertion and torquing the screws 174. If desired, eachsuch screw member may be provided a standoff sleeve 178 to provide apositive stop of the screws 174; alternatively, the standoff functionprovided by the standoff sleeve 178 can be achieved by using aself-drilling screw having an enlarged shaft, or by using dual diameterthreading which assures proper dimensional standoff as thread engagementoccurs. Also, longitudinal sides 179 of the foam spacer 172 can besloped to correspond generally to the crushed shape of the insulation60.

FIGS. 7 and 7A show yet another alternate means for supporting andattaching the roof panel member 160 to the underlying support spacer 26.A rigid panel support member 180 is supported directly on the upper beam30 and the screws 174 extend downwardly through the roof panel member160 to attach to the upper beam 30. No standoff member is necessary forthe screws 174 as opposing walls 182 of the channel shaped panel supportmember 180 exert countering forces to the screws 174, the roof panelmember 160 being supported on upper portion 184 of the panel supportmember 180. Bottom knife edges 186 of both walls 182 are tapered topresent a relatively sharp knife edge profile which serves to cutthrough the insulation 60 with installation of same. Disposed along thelower most portion of the bottom knife edges 186 are standoff tip 188portions which are brought to rest upon the vapor membrane of theinsulation 60 (if said insulation is provided with such membrane) orupon the flexible membrane 124 if it is disposed to support theinsulation 60 as described above. The standoff tips 188 serve to preventthe bottom knife edges 186 from severing the vapor membrane.

While the panel support member 180 is shown as extending continuouslyalong the supporting spacer 26 in FIG. 7, it will be apparent that thelength and configuration of such panel support members is one of designchoice for a particular application. That is, it may be desirable toprovide a plurality of shorter panel support members at spaced apartintervals beneath the roof panel member 160, and while it is generallythought best to pass each screw 174 through an underlying panel supportmember, there may be instances where such fasteners will be placed atpanel areas not directly over a panel support member. It may bedesirable to equip such individual fasteners with standoff sleeves 178such as shown in FIG. 6.

Shown in FIGS. 8 and 8A is a clip member 190 which incorporates thesupporting and insulation curing features of the panel support member180. The clip member 190, a joint hold-down clip that serves the samepanel attaching function of the clip member 138 shown in FIG. 2, has anupstanding web portion 192 with an upper hook portion 194 that engagesthe male sidelap joint of a standing seam panel such as at male sidelapjoint portion 162 shown in FIG. 5. The clip member 190 has a base legportion 196 extensive from and supporting the web portion 192, and asupport shelf 198 is also extensive from the web portion 192. As shown,the base leg portion 196 and the support shelf 198 extend in oppositedirections from the web portion 192, and if desired, the support shelf198 is cut from the central part of the web portion 192 and form bentinto the configuration shown, leaving a profiled hole 200 therein. Ifdesired, strengthening ribs 202 can be provided in the web portion 192.

The base leg portion 196 is channel shaped and has a pair of clipsupporting opposing walls 204 extending downwardly from an upper portion206 having one or more strengthening ribs 207 as shown. Bottom knifeedges 208 of both walls 204 are tapered to present a relatively sharpknife edge profile which serves to cut through insulation (not shown) inthe manner discussed for the panel support member 180 of FIG. 7.Disposed along the lower most portion of the bottom knife edges 208 aremultiple standoff tip portions 210 which are brought to rest upon thevapor membrane so as to prevent shearing of same by the bottom knifeedges 208 and to prevent the clip from turning on the surface supportingsame.

The support shelf 198 is disposed to support the male sidelap jointportion of a standing seam roof of the type shown in FIG. 5, andalthough no clip is shown in FIG. 5, the use of clip member 190 ispresented as an alternate to, or addition to, the panel attaching meansdisclosed in that figure. As shown, the support shelf 198 is supportedby the web portion 192 and by a leg portion 212 which also has thebottom knife edge 208 with standoff tip portions 210 that serve thepurpose discussed above.

The clip member 190 permits the placement of insulation, such as glassfiber batting or foam, for example, directly over the underlying supportstructure, be that purlins, joists or support spacers, while yetaccommodating direct joint attachment with substantially full insulationintegrity thereat. The attachment of clip member 190 is achieved viascrew fasteners (not shown) which extend through apertures (not viewed)in the upper portion 206 of the base leg portion 196 and which attach inthe manner described above with regard to the screws 174 (FIG. 7). Theclip member 190 can be used in combination with other attachment means,such as, for example, the foam spacers 172 (FIG. 6), the panel supportmembers 180 (FIG. 7) or with many other configurations.

To further improve the structural strength of the panel, while at thesame time maintaining its watertightness, the panel is attached to theunderlying supporting structure in such a manner that the stressconcentrations that normally occurs in the panel at the points ofattachment are minimized. Because the negative moment in the panel atthe attachment is high, but drops off very rapidly, it is possible togain a superior benefit at a minimum cost by extending the length of theclip past present practices. This results in a substantial reduction inthe maximum moment that must be resisted by the panel and at the sametime reduces the tendency of the male portion of the panel to pull outof, or unroll, the retaining portion of the female. The present clip maybe used to do this economically and effectively. The reason for this isthat the upper portion of the clip is an integral part of the lowerportion of the clip, and the complicated slide mechanisms required inmany past solutions are avoided. This enables the length of the clip tobe extended economically. A clip equal to, or longer that 0.083 of thepanel span between supports has been found to be very advantageous andto greatly improve the performance of the panel under wind upliftconditions.

A yet further alternate panel attaching means is shown in FIG. 9 whereinis shown a panel 160C which is intended to be of the same constructionfeatures as those of the roof panel member 160 (FIG. 5) except formodification to corrugation crowns 166C and 168C. This pair ofcorrugation crowns 166C, 168C have oppositely facing hook portions 220,222 respectively, and oppositely facing hooking clips 224 and 226 arehooked therein as shown. Each of the hooking clips 224, 226 has a baseleg portion 228 through which extends a screw fastener 229 that securessame to the underlying structure.

The spaced apart relationship of the standing seam joint and thestructural corrugation crowns 166C and 168C should be established sothat, when the panel 160C is subjected to upwardly directed load, thecatenary forces created as the panel 160C bows up under load will pullthe panel corrugations more tightly against the hooking clips 224, 226.This effect will be discussed more fully hereinbelow with relation toFIGS. 9A and 9B which are semi-detailed schematical representationsdealing with the forces on the panel 160C. At this point it issufficient to note that, as the medial portion of the panel 160C issecurely attached to the underlying structure, load conditions increaseup to the point of metal failure of the hooking clips 224, 226, acondition well within predictable control of the designer.

The panel 160C is also shown in FIG. 10, but with an alternate attachingmeans securing it to the underlying structure. An insulation boardassembly 230 comprises a semi-rigid foam insulation board 232 overlayingand may be previously (factory) adhered to a metal support plate 234.Hooking clips 224A and 226A are partially cut from the support plate 234and form bent to extend upwardly from the remaining portion of thesupport plate through holes 236 in the insulation board 232 to engagethe hook portions 220 and 222, respectively, of the corrugation crowns166C, 168C. FIG. 10A, a partial cross section, shows this form bentconfiguration of the hooking clip 224A more clearly. Plural screwfasteners 229A are supported by the insulation board 232 (as shown inbroken line view) until placement of the board onto the insulation 60;then the fasteners 229A are secured to the underlying structure asshown, with the heads of the fasteners 229A being finally securelyagainst the support plate 234. Sides 238 of the insulation board arepreferably tapered upwardly to generally conform to the crushed portionof insulation 60 over the underlying structure.

With regard to the center hold-down described in FIGS. 9 and 10, this isa unique system not previously used in the metal roofing industry. Whilecenter hold-downs have been utilized with non-standing seam panels, suchprior art devices have had numerous defects. One principal benefit ofthe center hold-down described herein is that the panel 160C is drawnmore tightly against the underlying hooking clips 226 (or 226C) as thepanel is subjected to wind uplift. The reason for this is that the panelis proportioned in such a way that as wind creates a suction over thepanel and the panel bows upward, the center span, which is longer thanthe two outside spans exerts a net force counter to the direction theclip points. That is, when the panel is subjected to a uniform outwardlydirected load, as would be encountered in wind uplift, the panel flatareas between the center and side hold-down clips bow upward because thetransverse flats of the panel have virtually no transverse bendingresistance and the panel forms a catenary between panel hold-down clips.

As the panel 160C bows upward, it will exert both a horizontal andvertical force on the side clips as well as on the center clips. Thehorizontal force is developed because the flat of the panel becomes acatenary and a catenary requires its end supports to exert bothhorizontal and vertical forces to resist only a vertical load. This isdifferent than normal beam action which requires that the end of thebeam resist only equal and opposite loads to be in equilibrium. Otherfactors being equal, a longer catenary will exert a greater horizontaland vertical force than a shorter one. Also, the greater the curvaturethe less the horizontal load required to keep the system in balance.

With reference to FIG. 9A, as flat areas A, B and C of panel 160C bow upas indicated by A1, B1 and C1, this results in a very stiff structurallystrong panel in the longitudinal direction. The load delivered to thepanel hold-down connector while in this configuration can be dividedinto components or vectors which are deemed to act both horizontal(parallel to the original panel flat in a transverse direction) andvertical (perpendicular to the original panel flat). The amount andrelationship between these two force components or vectors will bedetermined by the relationship between the spans between panel hold-downconnectors and the initial relative tightness of the catenaries,provided other factors such as unit upwardly directed load, materialthickness, etc. are constant.

The greater the unit uplift load, the greater the bow between panelhold-down fasteners will become. As the unit uplift load increases, thehorizontal component at the end of each bowing panel flat will increase.Since the panel is continuous over the center, non-penetrating,hold-down fasteners, these loads will be off-setting to the extent ofthe lesser load. The difference between the greater and the lesser loadswill be resisted by the non-penetrating, center hold-down fastener.Since the width WB of center span is greater than the widths WA and WBof the two outside spans, the net between the two loads will always bedirected in such a way as to pull the panel against the non-penetratingcenter, hooking clips 224, 226.

Because the center span B between the attachment points is wider thanthe outside spans A and C, and the three sections composing the panelare joined at the juncture over the center hold-down clips, the netforce inward at the center hold-down clips will always be greater thanthe net force out, thus pulling the panel more tightly against theclips. This is depicted in FIG. 9B where H1 represents the horizontalforce that results from the outwardly directed load being applied toflat A of the panel. H2 represents the horizontal load resulting fromthe outstanding directed load applied to panel flat B. In thisconfiguration H2 will always exceed H1 during uplift and this differencemust be offset by the force H3 developed in the center hooking clip 226.Thus, H3 which is opposite to H2 will increase as the load increases,thus forcing the panel 160C more securely against the center hookingclip 226. The opposite effect will occur at the center hooking clip 224located between WB and WC, and the pair of hooking clips 224, 226 willcooperate to hold the panel 160C securely to the underlying structure.

The total outward force on the center hooking clip 226 resulting fromits connection to panel 160C is represented by V1 and will be equal andopposite to the hold-down force V2 required to be exerted by the hookingclip 226. Thus, since forces V1 and V2 are balanced, and the differencebetween forces H1 and H2 is offset by force H3, the joint is seen to bein equilibrium with the net force holding the panel against the clip.

Although the center hold down mechanism, when properly located, willreduce the force tending to separate the male from the female panelcorrugation at the assembled sidelap, the panel female sidelap may stillseparate from the panel male sidelap as the panel flats A and C bowupwardly to form A1 and C1. If the length of the panel flats A and C arereduced sufficiently in relation to the length of flat B, the forces onthe panel sidelap will be reduced accordingly and separation will beminimized.

In summary, FIGS. 5 and 9A both possess similar benefits relating to thestrength, watertightness, and economy of the respective roof systemsdisclosed therein. However, the roof panel member 160 shown in FIG. 5 isrigidly attached to the underlying support structure by means ofconventional fasteners such as self-drilling, self-tapping screws. Bycontrast, the panel 160C shown in FIG. 9 and FIG. 9A is allowed to movelongitudinally in relation to the underlying support structure as aresult of the clip member 190 and hooking clips 224 and 226.

The roof panel member 160 in FIG. 5 is attached to the underlyingsupport structure with a through fastener in such a manner that thepanel and the underlying support structure are rigidly attached. Inother words, the roof panel member 160 cannot move in relation to titsunderlying support structure at the points of attachment. The benefit ofthis is that the diaphragm strength of the panel may be used to supportthe underlying support structure and hold this structure in place.Furthermore, if the underlying support structure is constructed to havesufficient rotational flexibility about its lower point of fixity, orthe top of the support structure is not braced so that it can move inthe direction of the panel's length, the underlying structure will beallowed to "float" as the panel expands and contracts in response toenvironmental forces. This is further described in copending U.S. patentapplication entitled FREE ROOF ASSEMBLY FOR REROOFING A BUILDINGSTRUCTURE, Ser. No. 08/181,756, filed Jan. 21, 1994, incorporated hereinby reference. Further, the roof panel member 160 and the underlyingsupport structure form a cooperative mechanism in which the underlyingsupport structure supports the roof panel member 160 while the roofpanel member 160 is free to change length when subjected to temperaturechanges without detrimentally affecting the performance of the overallmechanism.

The center panel flat B shown in FIG. 9A, by contrast, is attached toits underlying structure in such a manner that the panel is preventedfrom separating or moving away from its underlying support structure atthe center points of attachment. However, the panel may still movelongitudinally in relation to its underlying support by means of asliding mechanism, which is the hereinabove described clip member 190and hooking clips 224, 226), as illustrated in FIGS. 4, 4A-E, 8, 8A, 9,9B, 10 and 10A.

FIGS. 11-20

Turning now to a description of the roof panels 24, and consequently ofthe alternate roof panels discussed above, shown in FIG. 11 is a partialplan view of the roof panel 24 in which the four corners of same aredepicted as corners A, B, C and D, respectively. In FIG. 12A, asemi-detailed schematic of the roof panel 24 shows the position of theend lap sealant which is preferably factory installed prior to deliveryto a job site. Together with such end lap sealants, the sidelap sealantsform selective perimeter preplacement of the panel sealants, theadvantages of which will be discussed hereinbelow.

The profiles of the sidelap edges of roof panel 24 are depicted in FIG.13 in which the male sidelap edge of roof panel 24 is depicted ininterlocked relationship with the female sidelap edge an identicallyconstructed roof panel 24A. A description of panel corners A, B, C and Ddepicted in FIG. 11 will be provided hereinbelow following a discussionof the unnotched sidelap edges shown in FIG. 13. It will be understoodthat the sidelap seam described with reference to FIG. 13 relates tofactory-formed male and female sidelaps that are assembled by elasticdeformation, but that other sidelap seams having configurations withsimilarly advantageous features, such as offset clips that do notintersect the sidelap sealant and which have field roll formed seams maybe substituted for the factory roll formed seam described in FIG. 13.

In like fashion to the roof panel member 160 of FIG. 5 discussed above,the mating side edges of the roof panels 24 and 24A of FIG. 13 form astanding seam joint 240. Vertically extending male sidelap portion 242of roof panel 24 is engaged by vertically extending female sidelapportion 244 of the roof panel 24A. More specifically, female sidelapportion 244 extends along one longitudinal edge of the roof panel 24Aand has a first female leg portion 246 which extends upwardly from amedial portion 248A of the panel 24A. Also, the female sidelap portion244 has a second female leg portion 250 extensive from the first femaleleg portion 246 and forming an insertion cavity therebetween. The secondfemale leg portion 244 has an upper flat portion 254 and a downwardlyextending portion 256. Lower edge portion 258 of the downwardlyextending portion 256 is folded and bent inwardly to form an edgeretaining lip 260 which has an incline (measured from a plane parallelwith the medial portion 248A) as indicated by an arrow at incline 262.The incline 262 can vary over a wide range, and is preferably betweenabout 0 degrees and about 45 degrees.

The male sidelap portion 242 extends along one longitudinal edge of theroof panel 24 and has a first male leg portion 264 which extendsupwardly from a medial portion 248 of the roof panel 24. Also, the malesidelap portion 242 has a second male leg portion 266 extensive from thefirst male leg portion 264 and forming a male apex portion 268therebetween. Another portion of the second male leg portion 266 issubstantially parallel to the upper flat portion 254 of the femalesidelap portion 244, thus forming a sealant engaging ramp 270. Loweredge portion 272 of the second male leg portion 266 is folded to form amale exterior edge 274.

The profile of the male sidelap portion 242 is determined in dimensionalconfiguration to be received in an insertion cavity 252 of the femalesidelap portion 242. A sidelap sealant 276, which may be factoryinstalled, is adhered to the inner surface of the upper flat portion 254of the female sidelap portion 244, and upon entry into the insertioncavity 252, the sealant engaging ramp 270 of the male sidelap portion242 is brought into pressing engagement with the sidelap sealant 276.This is a unique feature of the standing seam joint 240; not only is thesidelap sealant removed from the male apex portion 268 to avoid sealantcontact with the clip hook portion 142, the spring like configuration ofthe male leg portion 266 assures superior performance in sealant to malemember contact.

The disposition of the edge retaining lip 260 of the female sidelapportion 244 requires overdriving of the male leg portion 266 duringinsertion so as to clear the uppermost tip of the edge retaining lip260, after which the male exterior edge 274 is brought to rest on theedge retaining lip as shown. The closing force required to accomplishthis is preferably supplied by a seam roller such as will be describedhereinbelow. Also provided hereinbelow with discussion of the seamroller is a discussion of the interaction of the component parts of thestanding seam joint 240 during assembly and seaming.

Meanwhile, it will be noted that the configuration of the male legportion 266 coacts with the female leg portion 250 as leaf like springsthat flex during insertion, and once the male exterior edge 274 clearsthe tip of the edge retaining lip 260, these springing members return tothe configuration shown in FIG. 13. However, due to the relative largeinsertion cavity 252 and the provision of the sealant engaging ramp onthe flexible male leg portion 266, there is always adequate space fornon-interfering fit of the components of the standing seam joint tocorrectly join without causing improper bulging joint interference.Improper bulging is caused when the male presses on the sealant so as tocause the sealant to develop sufficient pressure to in turn cause thesidelap sealant 276 to be displaced laterally outwardly and prevent themale exterior edge 274 and the edge retaining lip 260 from seatingproperly. Furthermore, the springing characteristic of the male legportion 266, together with the rolling of the lower edge portion 272,facilitates manufacturing of the standing seam joint 240 as these designcharacteristics greatly diminish dimensional criticality, thus allowinglarger rolling tolerances during the sidelap forming.

The standing seam joint 240 is shown in FIG. 13 with one of the clipmembers 138 positioned such that its upper hook portion 142 is hookedover the male apex portion 268 of the male sidelap portion 242. Also,support shelf 146 of the clip member 138 is shown in underlying supportof the roof panel 24 so as to back up the male sidelap portion and holdsame in a stable position as the female sidelap portion 244 is placedthereover. The clip member 138 is attached to underlying structure asdescribed hereinabove.

The roof panels 24, 24A are shown having a number of strengthening ribs278 (only two such strengthening ribs 278 being shown in FIG. 13), thepurpose of which is to stiffen the panels, especially in the verticallyextending portions and to increase the strength of the section whensubjected to longitudinal bending. Strength increase may come from boththe stiffening effect of the rib and the work hardening of the materialso as to effectively increase its tensile or compressive strength. Thepanel strengthening ribs, if they do not interfere with other panelfunctions, may be retained as shown herein, or if their retentioninterferes with other functions of the panel, the work hardening benefitmay be achieved by first forming the panel with the strengthening ribs278 and then immediately roll forming the panel to remove thestrengthening ribs. This selective localized work hardening increasesthe strength of the panel at critical areas and improves its performancewhen subjected to live load conditions. This strengthening is alsouseful in assuring joint snapping integrity, especially when selfsnapping is the sole form of closing pressure exerted, and the same isstill helpful with the employment of a seaming tool.

The insertion cavity 252 of the standing seam joint 240 is especiallyefficacious in obtaining joint sealant integrity. The substantiallyparallel upper flat portion 254 and sealant engaging ramp 270 serve tosecure the sidelap sealant in abutting engagement to form a sealing damall along the standing seam joint. At the end lap regions where thesidelap sealant 276 is predisposed to veer to contact the end lapsealants at one side of the insertion cavity 252 with sufficientlyarranged space to accommodate this veering. It will be readilyunderstood that the veering of the sealant may be achieved by increasingthe effective width of the sealant areas by means of adding filled orfactory applied sealant at the end lap areas. This will become moreclear in the discussion of the four corner juncture area below, and itis sufficient to note that the sidelap sealant comprises a longitudinalstrip of sealant which is supported alternately in a male joint abuttingmode in which mode the sealant strip is in abutting engagement with thesealant engaging ramp 270, and in a juncture mode in which the sidelapsealant 276 is in a position to abut the end lap sealants. Further, thesidelap sealant 276 in its male joint abutting mode, is positioned atclip locations to avoid contact with the male apex portion 268 so thatthe stationary clip members 138 do not tear the sidelap sealant 276 asrelative movement occurs between the roof panels 24 and the clip members138.

This simple, yet important, sealant arrangement is a significantdeparture from prior art treatment of joint sealant placement. In mostcases, the placement of sealant is almost an after thought of thedesigner, since mastic type sealant is disposable at will in the joint.However, water tightness of the joint suffers from such designtreatment, as can be verified by ordinary observation of roofs; roofleaks are probably the most common complaint and certainly one of theleast appreciated. In the standing seam joint 240, the designaccommodates the longitudinal extension of the sidelap sealant 276 withminimal disturbance (excepting the aforementioned veering at the fourcorner juncture areas), and with this preestablished disposition of thesidelap sealant strip, the abutting components of the joint uniformlyinteract therewith to enhance water tightness integrity.

The sidelap sealant 276 preferably is comprised of a resilient materialsuch as closed cell foam, but it may also consist of a flowable (butyltype) material. Both of these sealants are conventionally employed inthe building art, and are thus well known to a person of ordinary skillin this art. FIG. 14 shows an alternate and unique combination sealant280 in which both a resilient foam and flowable materials are utilized.A first foam sealant portion 282 has a channel 284 formed in its bottomsurface 286. The channel 284 is filled with a second sealant portion 288which is a flowable type of sealant material. The second sealant portion288 may have a protruding exterior meniscus 290 for wetting contact withabutting joint components. The advantage of the combination sealant 280is that the body of the sealant is readily maintained in resilientdamming action while the flowable sealant portion assures contact evenshould compressive forces diminish in any given zone along the joint.Mother, and perhaps the principal, reason for the combination sealant280 is that the closed cell foam retains a more nearly constantdurometer throughout a wide temperature range while the flowable sealantdoes not. On the other hand, the flowable material will flow into cracksand crevices at a panel joint to seal off these channels while theclosed cell foam will not.

Returning now to FIG. 11, wherein is shown portions of the roof panel 24in plan view, along one longitudinal edge is disposed the upstandingmale sidelap portion 242, and along the opposing longitudinal edge thereis disposed the upstanding female sidelap portion 244. Selectivenotching of the male and female sidelap portions occur at the corners A,B, C and D in order to facilitate interlapping with contiguouslydisposed roof panels. FIG. 11 displays this notching, as follows: atcorner A, notch A extends from lateral edge 292; at corner B, notch Bextends from opposing lateral edge 294, and external side edge 296 ofthe male sidelap portion is swaged to feather it slightly inward; atcorner C, notches C1 and C2 extend from the lateral edge 292; and atcorner D, there is no notch. Notch B is shown in FIG. 11 before optionalswaging and in FIG. 15A after same. The elevational profile of thesenotches will become clear with the discussion below. Sealant may befactory applied across one end of the roof panel 24 as indicated in FIG.12, which shows the positioning of same.

FIGS. 15A through 15C depict the placement of four contiguously disposedand interlapped panels at a four corner juncture area 300; theseinterlapped panels will be designated 24, 24A, 24B and 24C, all of whichare of similar construction. The roof panel 24 has the unique ability ofbeing installed both in a left to right or a right to left layingprogression. It also possesses the unique ability of being attached witha one piece clip that slides on or moves in relation to the top of themale corrugation. This feature is a unique advantage but requires aspecial configuration be incorporated in the end lap joint and may beutilized in other standing seam panel side laps in which the top of themale corrugation and the side lap sealant do not coincide. (i.e. thesealant is moved outside of the top of the male corrugation so the clipmay slide on the top of the male without breaking the side lap sealantseal such as occurs in FIGS. 30, 31, 33 and 34.) Returning to FIGS. 15Athrough 15C, an upslope direction 302 is indicated by the arrow thuslymarked, and corner A of roof panel 24 is downslope on the first panelinstalled in this instance. (FIG. 15A) Corner B of roof panel 24A islapped over corner A of roof panel 24, which has an optional factoryapplied end lap sealant placed thereon as shown. Corner B has a slottedhole 304 that is disposed over slotted hole 304 of Corner A. Next (FIG.15B), corner C of panel 24B is positioned to interlock its femalesidelap portion 244B over the male sidelap portion 242 while placingcorner C adjacent to the panel 24B as shown. Then (FIG. 15C), panel 24Cis positioned to interlock its female sidelap portion 244C over malesidelap portion 242A of roof panel 24A and over substantially all of thenotched portion (C2) of the female sidelap portion 244B of panel 24B,and to position corner D adjacent to corner B while overlapping cornersA and C as shown.

As shown in FIGS. 15C and 15D, notch C2 of panel 24B is slightly longerthan the overlapping portion of corner D of panel 24C which whenassembled is designed to line up with corner B. That is, a lateral edge294C of panel 24C (at corner D) will theoretically line up with lateraledge 294A of roof panel 24A (at corner B). However, in actual practice,the underlying supporting structure is often misaligned or out ofsquare, and it may be necessary to move the position of corner D so thatlateral edge 294C is out of line with lateral edge 294A by as much asabout one eighth of an inch or more. The extra length of notch C2permits this adjustment without metal interference, and the slotting ofholes 304A an 304B permits this positioning while yet lining up theseholes sufficiently to permit the passage therethrough of the connectingscrew fasteners.

FIG. 15D is an elevational view of the four corner juncture area 300showing portions of each of the corners A, B, C and D as these cornersinterlap. FIGS. 15E and 15F depict views taken as indicated in FIG. 15D.In FIG. 15E, the notches in roof panels 24 and 24A (corners A--notch Aand corner B--notch B) in the male sidelap portions 242 and 242A,respectively, have removed the upper parts of these sidelaps so that thefirst male leg portions 264, 264A extend into sealant 276C carried bythe over extending female sidelap portion 244C. The notch C1 in panel24B has cut a first female leg portion 246B of the panel innoninterfering disposition as shown. In FIG. 15F, notch C2 has removed asmall portion of a flat portion 254B and a downwardly extending portion256B of a second female leg portion 250B so that a substantial portionof upper flat portion 254B is received in an insertion cavity 252C. Inthis latter view, it will be seen that a sealant 276B is indented by themale leg portions 264, 264A. The other sealants also are displayed,denoting the complete sealant damming that is effected.

Another view of the sealant placement and notching is depicted in FIGS.15G through 15J. FIG. 15G is a partial side view of corner A of the roofpanel 24 in which is shown the end lap sealant extending along thevertical male leg portion 264 of the male sidelap portion 242, alsoshown in the end view of FIG. 15GG. Notch A, extending as shown, has ahorizontal edge 307G, and an angularly disposed sealant fillet 308Gextends from the edge 307G upwardly, thereby serving as a transitionbetween horizontal edge elevations of notch A. This is an importantfeature of the present invention in that the sealant fillet 308G avoidsthe open areas that result in the abrupt edges found in prior art cornernotching wherein the sealant, unable to make sharp turns, is oftenunsupported (separated from the panel) at notch corners and creates anopening through which water can pass to the interior of the building.Contrary to such prior art notching, the sealant fillet 308G providescontinuity of sealant contact, leading to water tightness enhancement atthe four corner juncture area 300.

FIG. 15H shows a similar view of the corner B of roof panel 24A. NotchB, extending as shown, has a lower horizontal edge 307H and an upperhorizontal edge 309H, with an angularly disposed sealant fillet 308Hthat serves to transition between the horizontal edge elevations ofNotch B. The sealant fillet 308H serves the function discussed abovewith regard to the sealant fillet 308G (FIG. 15G).

FIG. 15I shows a partial end view of corner C of panel 24B, with an endview there shown in FIG. 15II. Notch C2, extending as shown, exposes thesidelap sealant of panel 24B, and the end lap sealant is adhered alongthe panel to extend up the female leg portion 246B of the female sidelapportion 244B and on the female leg portion 250B (actually, the end lapsealant is only partially supported at the female leg portion 250B asthe sealant partially extends without support above leading sloping edge209I.

FIG. 15J is a partial end view of corner D of panel 24C showing sidelapsealant veered to its edge engaging mode in order to be sealinglycontacted with the upstanding male leg portions (as at 264 and 264A inFIG. 15E).

FIGS. 16A through 16F, to be explained more fully below, display theinstallation sequence when the roof panel 24 is used on the oppositeroofing slope. Meanwhile, completion of the four corner juncture area300 will be described by referring to cinch strap 310 assembly shown inFIG. 17 which comprises a bar strip 312 that has a length dimension 314which extends between the male and female sidelap portions of the roofpanel 24. For simplifying this discussion, the bar strip 312 is depictedas a straight member, but it will be understood that the medial portionof the bar strip will be configured to fit over any corrugation crownsthat the roof panel 24 (or appropriate panel) may have. The first end316 of the bar strip 312 has a joint strap 318 portion that is shaped tofit over the standing seam joint 240. The joint strap 318 has a firstleg portion 320 and a second leg portion 322 interconnected by agenerally horizontal portion 324. The second leg portion 322 has anangular set as shown, and base leg portion 326 extends from the distilend thereof. A plurality of holes 328 are disposed along the cinch strap310 which are predetermined to overset the slotted holes 304 in the endsof the roof panel 24. When the joint strap 318 is placed over thestanding seam joint 240, the leg portion 326 is forced against themedial portion of roof panel 24, and as indicated by the dashed lines322A and 326A, which depict the final position of the joint strap 318(just before attachment), the leg portion 322 is shorter than the legportion 320 by a distance 330 which is greater than the thickness of thebar strip 312. Thus, when the base leg portion 326 is forced against themedial portion of the roof panel 24 by screw fasteners, the joint strap318 will be caused to compress the standing seam joint 240 whereuponsealing integrity is enhanced. Finally, at the other end 332 anupstanding lapped leg portion 334 is disposed. When the cinch strap 310is overlapped by the joint strap 318 of a contiguous cinch strap ofidentical construction, the lapped leg portion 334 is secured therein.

To secure the cinch strap 310 in place over the four corner juncturearea 300, a companion backup plate 340, shown in FIG. 18, is provided.When installing the cinch strap 310 assembly, the screw fasteners thatare placed through the holes 328 and 304 of the cinch strap 310 and roofpanels 24 respectively, a nut plate is provided since the thin gagepanel material is not usually suitable to distribute the screw fastenercompression load over the desired compression area or retain long termcompression integrity of the juncture area 310. This nut plate musteither be held in place by a worker under the panels, which is usuallynot feasible, or it must be held in position by mechanical means. Thepresent invention presents a novel mans of placement and retention ofthe backup plate 340 prior to installing the cinch strap 310.

Returning to FIG. 11, a plurality of stirrup connectors 342 are disposednear the lateral edge 292 or the lateral edge 294 of the roof panel 24.While the stirrup connectors 342 are shown at both ends of the roofpanel 24, this is illustrative only, and it will be understood that suchstirrups may occur only on the bottom one of the end lapping panels. Anenlargement of one of the stirrup connectors 342 is shown in FIG. 19,this connector comprising a support platform 344 which is partially cutfrom the panel metal and embossed downwardly. As shown in FIGS. 19A and19B, the support platform 344 has a pair of supporting side walls 345and is open at ends 346 and 348, with end 346 having an entry lip 350turned slightly downward. A pair of detent ribs 352 are embossed toextend upwardly from the upper surface of the stirrup connector 342.

With further reference to FIG. 18, the backup plate 340 comprises anangularly profiled member having an upper planar surface 354 with pluralguide holes 356 disposed to align with slotted holes 304 that aredisposed near the ends of roof panels 24 and 24A. The length of thebackup plate 340 is sufficient to back up the cinch strap 310 assembly.As also shown in FIG. 20, relief areas 358 are cut in the backup plate340 to expose a pair of extensive stirrup engaging tabs 360 that arespatially determined to be slidably received by the pair of extensivestirrup connectors 342 supported beneath roof panel 24 near lateral edge292. Each such stirrup engaging tab 360 has an embossed detent rib 362as is viewable in FIG. 20. When the stirrup engaging tab 360 is movedinto the opening at end 346, it passes unrestrictedly and its detent rib362 passes over the detent ribs 352. These latter mentioned detent ribs352 serve to resist removal of the stirrup engaging tab 360 once it isin support engagement with the support platform 344, thus assuringretention of the backup plate 340 beneath the lower most roof panel 24at the four corner juncture area 300. The stirrup engaging tabs 360,having an arrow point shape as shown, serve to guide the backup plate340 during assembly into its proper position. The dimensions of therelief area is determined such that tab edges 363 are brought to restagainst the ends of the side walls 345 of the stirrup connectors 342.Further, tab edges 366 of the stirrup engaging tabs 360 are disposed tobe in near proximity to the side walls 345 of stirrup connectors 342once the backup plate 340 is installed, thus disposing the backup platewith a degree of precision placement that assures proper alignment ofthe guide holes 356 (of backup plate 340), slotted holes 304 (of thelapping panels) and 328 (of the bar strip 312 of the cinch strap 310assembly). This aligning feature of the present invention facilitatesthe installation of the cinch strap 310 assembly and assures quality endlap sealing.

With the backup plate 340 in place, screw fasteners are placed throughthe holes 328 (in the cinch strap 310 assembly) and slotted holes 304(in the overlapping roof panels), and threadingly engaged with the guideholes 356 in the backup plate 340, which, like the bar strip of thecinch strap, is of sufficient thickness to endure the compressive forcegenerated on the four corner juncture area to ensure water tightnessintegrity. It will be understood that the backup plate may be used atsidelaps as well as endlaps, as desired, to increase the stiffness ofthe roof panels and to provide resistance to unfurling and unzipping ofthe standing seam.

An alternative backup assembly to be used in lieu of the backup plate340 is shown in FIG. 18A. The backup plate 340 is a separate componentwhich is supported beneath the bottom panel at the lapping area via thestirrup connectors 342 formed in the roof panel 24 as required. A backupassembly 340A is formed integrally with the modified roof panel 24Eshown in FIG. 18A. The panel 24E is the same as described above for roofpanel 24 with the exception that a lateral edge 292E of the panel flatis extended and is form bent to have a plurality of stiffening runs 364beneath the end of the panel 24E, as shown more clearly in the enlargedcross sectional view of FIG. 18B. A nut platform 367 is shaped to extendfrom the stiffening runs 364 just beneath the panel flat, and holes 368are formed therein just below, and registered with, the slotted holes304 in the panel 24E. Preferably, the holes 368 are punched andtubulated into, or with, the slotted holes 304 so that the walls of theholes 368 project into the slotted holes 304 in the manner shown. Thestiffening runs 364, provided in the number, shape, and dimensionnecessary, serve to strengthen the panel flats at the four corner areas,and the holes 368 are appropriately sized such that the nut platform 367serves as an integrally formed nut for the screw fasteners that securethe cinch strap 310 assembly to the four corner juncture area.

As mentioned above in the discussion of the four corner juncture area300, FIGS. 15 through 15F depicts the lapping sequence of installing theroof panels 24 with the roof upslope direction being that indicated bythe upslope direction 302 arrow. The roof panels are unique in thatprogression of panel installment can also proceed in similar fashionwhen the roof upslope direction is reversed, as when dealing with theroof section on the other side of the roof ridge. FIGS. 16A through 16Fdepict this lapping procedure when the upslope direction is thatindicated by arrow 302R. The same numerical designations will be used inFIGS. 16A-16F to indicate identical components appearing in FIGS.15A-15F.

In FIG. 16A, the upslope direction of the underlying support structureis depicted by arrow 302R, and corner B of roof panel 24A is nowdownslope. Corner A of roof panel 24 is lapped over corner B and on topof the end lap sealant that is preferably factory installed on roofpanel 24A in the position shown. Next (FIG. 16B), corner D of panel 24Cis positioned to interlock its female sidelap portion 244C over the malesidelap portion 242A at corner B. End lap sealant is disposed on panel24C as shown, preferably at the factory. Then (FIG. 16C), panel 24B ispositioned to interlock its female sidelap portion 244B over the malesidelap portion 242 of roof panel 24 and over the female sidelap portion244C of corner D (panel 24C).

FIG. 16D is an elevational view of a four corner juncture area 300Rshowing portions of each of the corners A, B, C and D as these cornersinterlap. The notching of the panels is the same as discussed above withregard to four corner juncture area 300, so it is sufficient to noteonly the differences thereof relative to comparing the view of FIG. 16Eto that of FIG. 15E, and the same is true relative to a comparison ofFIGS. 16F and 15F. It will be noted that the bottom panels in FIG. 16Eare roof panels 24A and 24C, and that the first female leg portion 246B(corner C of panel 24B) is now outboard to the female sidelap portion244C (corner D of panel 24C). The notched first male leg portions 264,264A (of corner A and corner B, respectively), although reversed inorder, still abut the sealant 276C in the insertion cavity 252C of panel24C. As depicted in FIG. 16F, the notched upper flat portion 254B(corner C, panel 24B) overlaps the female sidelap portion 244C (cornerD, panel 24C) with sealant 276B therebetween. After sealant is placedover the juncture area 300R, the above described cinch strap 310 andbackup plate 240 are joined via appropriate screw fasteners tocooperatively compress the lapped area.

FIGS. 21-22B

As mentioned hereinabove for factory roll formed panels, in reference toassembling the standing seam joint 240, the closing force required toachieve the interlocking of the male and female sidelap portions 242,244 of the roof panels 24, 24A (as shown in FIG. 13) is preferablysupplied by a seam roller 370 such as shown in FIG. 21. The closing, orseaming, of the standing seam joint 240 will be discussed following adescription of the seam roller 370 and an alternate thereof. It will beunderstood that a field roll seaming machine, which configures the panelto the desired shape, may be employed for panels whose shape incorporateconfigurations as shown hereinbelow with respect to FIGS. 30, 31, 33,and 39.

With reference to FIGS. 33, 33A and 33B, the seam roller 370 comprisesframe member 372 having a forward end 374 and a rearward end 376. A maleinsertion assembly 378 is supported by the forward end 374, and a femalebackup assembly 380. The male insertion assembly 378 comprises a firstsupport arm 382 preferably welded to extend normally to the frame 372and supporting an upstanding second support arm 384 that supports ashaft 386. A male insertion wheel 388 is rotatingly mounted on the shaft386 and is disposed for engagement with the underside of the malesidelap portion 242 as shown in FIG. 21A which is an end view of theseam roller 370.

The female backup assembly 380 has a support shaft 390 which issupported by the frame member 372 near its rearward end 376 to extendgenerally parallel to the first support arm 382. A female backup wheel392 is rotatingly supported by the support shaft 390 and has a trackinggroove 394 which is dimensioned to accept and track the female sidelapportion 244 of the roof panel 24A as shown in FIG. 21A.

The frame member 372 preferably is a tubular member having a minorangular bend 396 generally near the forward end 374, and a handle member398 (partially shown in the drawing) extends from the rearward end 376at an annular disposition or bend 400. The handle member 398 extends aselected distance and has a pair of hand grips 402 extensive from eachside thereof.

Once the female sidelap portion 244 has been positioned over the malesidelap portion 242 (in the assembly process of installing adjacent roofpanel members), interlocking of these female and male portions isachieved as follows. A workman, holding the handle member 398, causesthe male insertion wheel 388 to be placed beneath the male sidelapportion 242 in the manner depicted in FIG. 21A. Next, the workman, byrotating the handle member 398 toward the standing seam joint 240,causes the female backup wheel 392 to bear upon the top of the femalesidelap portion 244 as shown in FIG. 21B. The relational positions ofthe male and female backup wheels 388, 392 are determined such that theleverage of the handle rotation causes the male sidelap portion 242 tobe forced into the insertion cavity 252 of the female sidelap portion244, as shown, above the male insertion wheel 388. Finally, the workmanneed only pull or push the handle member 398 along the length of thestanding seam joint 240 with the handle member 398 in this position toforce sealing interlocking of the male and female sidelap portions 242,244. Once this has been achieved, disengagement of the seam roller 370is accomplished by the workman rotating the handle member 398 away fromthe standing seam joint 240 and removing the male insertion wheel 388from under the male sidelap portion 242.

Another embodiment of a seam roller constructed in accordance with thepresent invention is shown in FIGS. 34 and 34A-34B wherein seam roller410 comprises a frame member 412 having an upper channel shaped member414 having a tracking groove 416 and having upturned flared edges 417 atthe ends thereof. The tracking groove 416 is dimensioned to accept andtrack the female sidelap portion 244 of the roof panel 24A. The member414 serves as a backup assembly similar to that of the female backupassembly 380 described above the seam roller 370 (FIG. 21). A maleinsertion assembly 418 comprises a generally channel shaped member 420and a pair of spring biased hinges 422 which interconnect the member 420and the member 414, the hinges 422 being biased to rotate the member 420in the direction indicated by arrow 424.

The male insertion assembly 418 also comprises a latch assembly 426which is supported by the frame member 412 generally between the hinges422. The latch assembly 426 forms a groove between itself and the framemember 412 and a bolt plate 430 is disposed for sliding therein, thebolt plate 430 having a gripping portion 432 formed to extend generallynormal to its body portion and having an extending tab 434 that isclearingly received in a slot 436 such that the movement of the boltplate 430 is selectively permitted between a downward locking mode shownin FIGS. 22 and 22B, and an upward unlocking mode shown in FIG. 22A. Thelower edge 438 of the bolt plate 430 is beveled to reduce interferingcontact with the member 420, the member 420 being rotatable in adirection indicated by arrow 440 as a workman forces the bolt plate 430downward to its locking mode via the gripping portion 432. In thelocking mode, the bolt plate 430 extends below the lower edge of themember 414. When a workman pulls up on the gripping portion 432, thebolt plate 430 is retracted from engagement with the member 420, thuspermitting the biasing hinges 422 to rotate the member in the directionshown by arrow 424.

The channel shaped member 420 has a male insertion portion 442 that issupported for engagement with the underside of the male sidelap portion242 as shown in FIG. 22B when the bolt plate 430 is placed in itslocking mode. The male insertion portion has an upper edge 444 asdepicted by the dash lines in FIG. 22, with a rounded apex 446 being thecontact with the male sidelap portion 242.

The seam roller 410 further comprises a handle assembly 448 thatconnects to the frame member 412 as follows. A pair of upwardlyextending support plates 450 support a support rod 452 therebetween, andan apertured slide member 454 is slidably supported on the support rod452. Preferably, the support rod 452 is as at flatted 456, as is theaperture in the slide member 454, in order to orient the slide member asdepicted in FIG. 22. The slide member 454 has an angular upper portion458 to which a handle member 460 is attached. A pair of hand grips 462extend from opposite sides of the uppermost portion of the handle member460.

Once the female sidelap portion 244 of a panel, such as roof panel 24A,has been positioned over the male sidelap portion 242 (such as of panel24), interlocking of these members to form the standing seam joint 240is achieved as follows. A workman, places the frame member 412 of theseam roller 410 over the female sidelap portion 244, causing thetracking groove 416 to rest on top of the female sidelap portion. Next,the workman forces the bolt plate 430 into its locking mode whichrotates the male insertion assembly 418 so as to cause the apex 446 ofthe male insertion portion 442 to drive the male sidelap portion 244into the insertion cavity 252 of the female sidelap portion 244. As theworkman pulls or pushes, the seam roller 410 along the length of thestanding seam joint 240 using the handle 460, the cooperative effort ofthe male insertion portion 442 and the tracking groove 416 of the framemember 412, which serves as a female backup member, causes sealinginterlocking of the male and female sidelap portions 242, 244. Once thishas been achieved, disengagement of the seam roller 410 is accomplishedby the workman simply pulling the bolt plate 430 into its unlocking modewhich frees the male insertion assembly 418 to be rotated, via itsspring hinge members 422, out of engagement with the standing seam joint240, and the seam roller is then lifted therefrom.

Having now described the unique standing seam joint 240 (FIG. 13) andthe seam roller 370 (FIG. 21), together with alternate seam roller 410(FIG. 22), attention will now be directed to the dynamics of seamrolling as it relates to the present invention. With typicalsnap-together, standing seam joints it is possible to apply considerableforce to the top of the female portion of the corrugation and the bottomof the male corrugation to force the male and female components intoseating engagement. However, in the standing seam joint 240 of thepresent invention, the only force available to cause the male exterioredge 274 and the edge retaining lip 260 to become properly engaged isthe residual elasticity in the male and female leg portions 266, 250.Sometimes the residual elasticity of these components is not sufficientto cause them to seat properly because of imperfection in the formationor assembly of the panel and the fact the forward portion of the panelnot yet joined is elastically holding the joint apart so as to preventthese components from seating properly.

As shown in FIG. 21, there is a point where one joint edge actuallycrosses the other joint edge at an angle. It is only as the snaptogether process passes this point that the male edge may actuallybecome seated or fully engaged by the female edge. As the snappingprocess continues, and as the resistance to nesting lessens as thecross-over point proceeds down the panel, the male exterior edge 274begins to slide down the edge retaining lip 260. By this time the twovertical forces driving the joint together has likewise moved down thelength of the panel and it remains for the residual forces to seat themale and female edges properly. However, at this point, there is a forceexerted by the sidelap sealant 276 which tries to separate the jointcomponents, and there is a mutual residual elasticity trying to forcethe male exterior edge 274 into nesting engagement with the edgeretaining lip 260.

By having the inclination of the male leg portion 266 greater than theedge retaining lip 260 of female leg portion 250, it is possible tominimize the continued frictional engagement of the contacting portionsof these two components and greatly encourage them to seat properly. Ifthis is coordinated with an appropriate but limited amount of oversnap,it is possible to achieve a very desirable configuration with favorableseaming, or joining, characteristics. This will become clear as seamingof the standing seam joint 240 is considered.

With continued reference to FIG. 13: during the seaming operation, asthe male exterior edge 274 clears the upper most part of the edgeretaining lip 260, compression on the sidelap sealant 276 caused by theseam roller 370 is at the maximum. As soon as the male exterior edge 274begins to slide down the incline of the edge retaining lip 260, thecompressive force on the sidelap sealant 276 begins to diminish and theforce required to drive the male exterior edge 274 along the incline ofthe edge retaining lip 260 begins to diminish. However, if the angle 262of the edge retaining lip 260 is more than about 30 degrees, the sidelapsealant 276 must be too severely over compressed and friction betweenthe male exterior edge 274 and the edge retaining lip 260 is increasedaccordingly, thus preventing initial movement of the male exterior edge274 past the upper most portion of the edge retaining lip 260. Thisprocess is facilitated if both edges of these engaging components aresmooth and rounded, as shown, to enhance movement therebetween.

FIG. 23

Turning now to FIG. 23, depicted therein is an improved interlockingsidelap joint assembly 130, shown in partial cross-sectional,elevational view and which is a female/male interlock seam assemblyformed by the interlocking engagement of contiguously placed roof panels132A and 132B. The roof panel 132A has a female sidelap joint 134 formedalong one side thereof, the female sidelap joint 134 having a first legportion 136 and a second leg portion 138 extending therefrom and formingan insertion cavity 140 therebetween. A mastic cavity portion 142 isformed at the apex juncture of the first leg portion 136 and the secondleg portion 138, the mastic cavity portion 142 having communication withthe insertion cavity 140.

Along the opposing side (not shown) of the roof panel 132A there isformed a mating male sidelap joint which is identical in construction tothat shown in FIG. 23 as male sidelap joint 144, it being understoodthat the female sidelap joint along one side of the roof panel 132Abeing matingly interlocked with the male sidelap joint of thecontiguously placed roof panel 132B. Accordingly, a description of themale sidelap joint 144 in relation to the roof panel 132B will be aswell a description of the male sidelap joint disposed along the opposingside of the roof panel 132A. Further, it will be understood that theroof panel 132A has a medial panel portion (not shown) as previouslydescribed for the roof panel, and as shown in FIG. 23, the first legportion 136 of the female sidelap joint 134 extends substantially normal(at about a 90 degree angle) to the medial panel portion. Also, the malesidelap joint 144 has a first leg portion 146 that extends substantiallynormal to the medial panel flat portion (not shown) of the roof panel132B, and a second leg portion 148 extends angularly from the first legportion 146 and forms an apex portion 150 at the juncture of the firstand second leg portions 146, 148. As will be discussed below, the apexportion 150 is formed for entry into the upper mastic cavity portion 142when the male sidelap joint 44 is inserted into the insertion cavity 140of the female sidelap joint 134.

Returning to the female sidelap joint 134, it will be noted that thesecond leg portion 138 extends normally to the first leg portion 136 toprovide an upper flat portion 152 to the female sidelap joint 134; also,another downwardly extending portion 156 are provided, with the latterportion 156 forming a shoulder stop 158. The second leg portion 138 hasan edge engaging ramp 160 which extends generally toward the first legportion 136 and partially blocks the opening to the insertion cavity140. Further, it will be noted that the second leg portion 148 of themale sidelap joint 144 has a shoulder engaging portion 162 shaped tonest against the shoulder stop 158, and the end of the second legportion 148 defines a ramp engaging edge 164.

When assembled, the female sidelap joint 134 of the roof panel 132A ispositioned over the male sidelap joint 144 which has been previouslypositioned to rest upon several clip support members 52 along the sideof the roof panel 132B, and supported by upper portions 98 thereof,which serve to backup the flexible sheet metal of the male sidelap joint144. As the male sidelap joint 144 is caused to enter the insertioncavity 140, the first leg portion 146 of the male sidelap joint 144 isdisposed substantially parallel to the first leg portion 136 of thefemale sidelap joint 134; and the second leg portion 138 of the femalesidelap joint 134 is caused to flex open as the ramp engaging edge 164presses against the edge engaging ramp 160, causing the mouth of theinsertion cavity 140 to enlarge to receive the male sidelap joint 144.As the male sidelap joint 144 is caused to be received into theinsertion cavity 140, the apex portion 150 of the male sidelap joint 144is projected into the mastic cavity portion 142, which is partiallyfilled with a first mastic material 166, such as a bituminous material.

As this is occurring, the ramp engaging edge 164 is sliding along theedge engaging ramp 160 and finally, the shoulder engaging portion 162 isbrought into abutting engagement with the shoulder stop 158. Thedimensions of the second leg portion 138 and the second leg portion 148are predetermined such that the shoulder engaging portion 162 is inabutting engagement with the shoulder stop 158 when the ramp engagingedge 164 is at or near the center of the edge engaging ramp 160. Theramp engaging edge 164 and the edge engaging ramp 160 are positioned sothat at least one edge of ramp engaging edge 164 bites into edgeengaging ramp 160 as environmental forces tend to disengage the two.Further, the edge engaging ramp 160 may be provided a knurled topsurface 168 so as to resist disengaging movement of the ramp engagingedge 164 and ramp engaging edge 164 may be sharpened to bite into theedge engaging ramp 160. Once assembled, the second leg portion 138 andthe second leg portion 148 return to substantially their nonflexedpositions after the male sidelap joint 144 is matingly received withinthe insertion cavity 140 of the female sidelap joint 134. Configuringthe second leg portion 148 so that theoretically it is fully engagedwith the second leg portion 138 when the ramp engaging edge 164 is at ornear the mid point of the edge engaging ramp 160 allows the male sidelapjoint 144 and the second leg portion 138 to be fully engaged and lockedtogether even through minor manufacturing imperfections cause somedeviation from theoretical and locking can occur above or below the midpoint.

The above described arrangement provides a standing seam assemblywhereby the apex portion 150 of the male sidelap joint 144 is caused topenetrate the mastic cavity portion 142 and to reside therein at aposition determined by the locking engagement of the shoulder engagingportion 162 and ramp engaging edge 164 of the second leg portion 138between the shoulder stop 158 and the upper portion of the edge engagingramp 160, respectively. This locking engagement prevents relativemovement between the female sidelap joint 134 and the male sidelap joint144, preventing fretting of the first mastic material 166 with themovement that occurs because of thermal expansion and contraction orroof loading that occurs to the roof panels 132A and 132B.

As discussed hereinabove, a plurality of hold down clips 56 aresupported by the underlying building structure and disposed to interlockover the apex portions of the male sidelap joints in order to connectthe standing seam assembly to the building structure. Such hold downclips 56 are usually hooking members of about three to four inches inlength. Accordingly, the female/male sidelap joint assembly 130 mustaccommodate the intrusion of such clips at every bar joints or purlinintersection. Shown in FIG. 23 is one such location as the upper portion58 of the hold down clip 56 is hooked over the apex portion 150 of themale sidelap joint 144. The placement of such hold down clips 56 isperformed prior to interlocking the female and male sidelap joints 134,144, and as insertion is completed, upper portion 58 is caused toproject into the mastic cavity portion 142 and thus into the sealingengagement with the first mastic material 166.

As further insurance against this disengagement of the assembled femaleand male sidelap joints 134,144, end portion 170 of the upper portion 58is disposed to come into near proximity to a knurled clip retentionsurface 172 on the inwardly extending portion 156 of the second legportion 138 of the female sidelap joint 134. By "nearing proximity" itis intended herein to denote that the several elements underconsideration in the assembled position are dimensionally predeterminedsuch that the end portion 170 is caused to be brought into closeproximity (that is, either directly abutting or clearing same by a verysmall gap) so that the end of end portion 170 will bite into the surface172 as uplift forces tend to separate one panel from the other. Duringinsertion, the opening action of the second leg portion 138 of thefemale sidelap joint 134 relative to the first leg portion 136 haspermitted entry of the male sidelap joint 144 with its accompanying holddown clip 56; however, once the portions of the female and male sidelapjoints 134, 144 are relaxed in the assembled position thereof, any forcetending to cause separation of these two joints will cause the endportion 170 to be brought into engagement with the clip retentionsurface 172, thereupon providing another force that resistsdisengagement of the female and male sidelap joints 134, 144. Anencapsulating seal 174 is disposed in the inner cavity of the upperportion 58 which encapsulates the apex portion 150 in the assembledposition to provide a positive seal between the upper portion 58 and theapex portion 150 of the male sidelap joint 144.

The top of the female/male sidelap joint assembly 130 is believed uniquein that the mastic cavity portion 142 is relatively large as compared toprior art mastic cavities and prior art standing seam assembly joints.Further, the final assembled position of the apex portion 150 (and itsaccompanying upper portion 58) within the mastic cavity portion 142 isoffset from the center of the mastic cavity portion 142 so that screwattachment of a flashing sheet 176 is possible where required, such atroof or gutter edges. The sheet metal flashing sheet 176 can besupported on the upper flat portion 152 of the female sidelap joint 134,and a conventional sheet metal screw 178 can be used to secure itthereto. Sufficient space is provided in the mastic cavity portion 142that, together with the offsetting of the apex portion 150, the screw178 can penetrate the top of the female sidelap joint 134 without riskof penetrating the apex portion 150 or the upper portion 58. Further, alocator groove 180 can be provided in the upper flat portion 152 as anaid in positioning and guiding the screw 178, and a mastic bead 181 canbe placed on the underside of the flashing sheet 176 so as to besealingly adhered to the upper flat portion 152 when secured thereto.

Another feature of the mastic cavity portion 142 is the provision of asecond mastic material 182 within the mastic cavity portion 142 underthe locator groove 180 so as to contact and seal about the penetratingscrew 178. The difficulty with most prior art standing seam jointassemblies is that with most prior art standing seam joint assemblies isthat hydraulic pressures are generated on the mastic during jointassembly as the mastic is being penetrated by the male sidelap joint,which often causes joint opening, especially at the clip attachmentpoints. In prior art joints, if the mastic is caused to fill the entiremastic cavity, hydraulic pressure is built up with the insertion of themale joint member. That is, the displacement of the mastic in such priorart joints, especially at lower ambient temperatures at which the masticbecomes viscous, can and often does force the female and male sidelapjoints to separate. On the other hand, if the movement of the male jointmember in the mastic cavity caused by environmental influences causesthe mastic to be worked out of the joint with the fretting action of themale joint member. In the present invention, the provision of a secondmastic, namely a highly compressible mastic such as one of the foamvariety, permits the flowing first mastic material 166 a place in whichto expand while maintaining the seal that must be effectuated within themastic cavity portion 142. Of course, it will be possible in someapplications to simply omit the second mastic material 182 and leavethis portion of the mastic cavity portion 142 vacant, which stillprovides for the expansion and displacement of the first mastic material166.

In addition to the nonfretting feature of the female/male sidelock jointassembly 130 discussed above with regard to the mastic material, thepositive interlocking feature of the female/male sidelock joint assembly130 offers important advantages with regard to resisting jointseparation, sometimes referred to as "unzipping" which results fromrotational forces imposed on the joint by windlift on the medialportions of the panels. Of course, the non-penetrating attachingassembly of the present invention provides for anchoring of a medialpanel portions 68 of roof panels 26 to the underlying buildingstructure, and this prevents most of the rotational movement imparted tothe joints, but when the nonpenetrating attaching assembly is not used,or even when it is used, there will still be uplift on some portions ofthe roof panels, the result of which is to place some, if not a gooddeal, of rotational moment on portions of the female/male sidelock jointassembly 130.

The interlocking feature of the dual point gripping function of theshoulder stop 158 and the edge engaging ramp 160 abuttingly engaging theshoulder engaging portion 162 and the ramp engaging edge 164,respectively, serves to resist moment forces of disengagement imposed byrelative rotation of the roof panels 132A and 132B. Further, theinteraction of the end portion 170 (of the hold down clip 56) with theclip retention surface 172 also helps resist rotational forces.

It has been observed that the height and the width ratio of thefemale/male sidelock joint assembly 130 is also important. For thepurpose of unzipping considerations, the distance indicated by arrow 190will be referred to as the height (H) of the female/male sidelock jointassembly 130, and the distance indicated by the arrow 192 will bereferred to as the width (W) of the female/male sidelock joint assembly130. It will be appreciated that these distances measured from the pointof upward rotation (that is, from the point of contact of the rampengaging edge 164 with the edge engaging ramp 160), represent the momentarms applied during rotation that spring the leg portions of the femaleand male sidelap joints 134, 144 apart. Practical observations haveindicated that the ratio (R) of H to W has a direct bearing on theability of the joint to transfer force from the clip to the panel andfrom one panel to the other. As a result the unfurling and unzippingcharacteristics of the female/male sidelock joint assembly 30 aregreatly improved. If R is less than about 1.0, and for values up toabout 1.0 (that is, low and wide joints), there is more of a tendencyfor the joint to separate as the roof panel 132A is rotated relative tothe roof panel 132B. For values of R greater than about 1.0 (that is,for high, narrow joints), the tendency to unlock during rotationalmoment load is decreased. At a value of R of approximately 2.0 very goodlocking stability was observed during tests to separate the roof panels132A, 132B.

FIGS. 24 and 25

As previously described hereinabove, the unfurling and unzipping of thepanel sidelaps is undesirable and may be prevented in two ways. One wayto prevent unfurling and unzipping is to construct the sidelaps so as topossess sufficient rotational restraint to prevent a female panel fromrotating in relation to an adjacent male panel. A second way to preventunfurling and unzipping is to reduce or eliminate the forces that tendto separate the male and female panels from their interlockingly joinedrelationship.

Insofar as constructing sidelaps to possess sufficient rotationalrestraint to prevent a female panel from rotating in relation to anadjacent male panel, various prior art approaches have been formulated,such as the use of an external clip as disclosed in U.S. Pat. Nos.5,228,248, 5,282,340, and 3,312,028. These prior art approaches,however, have met with limited success as a result of consumer concernsrelating to aesthetics, corrosion induced by dissimilar metals and theretention of water between such a clip and the panels. On the otherhand, restraint mechanisms such as disclosed above with respect to FIG.23, and hereinbelow with respect to FIGS. 24, 25, 26, 30, and 31 havebeen found to provide sufficient rotational restraint without these andother associated problems.

As to the second way to prevent the unfurling and unzipping of adjacentpanels, that is the reduction or elimination of forces tending to causethe unfurling and unzipping of the panels, mechanisms disclosedhereinabove with reference to FIGS. 5 and 9A have been found to beadvantageous for that purpose. Furthermore, mechanisms to be describedhereinbelow with respect to FIGS. 26, 27, 28, 30, 31, 32, 33, 34, 35,41, 43, 42, 44, 47, and 48 wherein a restraining mechanism is appliedacross at least a portion of the panel flat or the panel joint may beemployed to reduce the force tending to separate the panels to anacceptable level.

Referring now in particular to FIG. 24, shown therein is a view of astanding seam assembly 130A, similar to the sidelap joint assembly 130previously described, but containing compression plates on either bothor one side of the steel roll formed interlocked sidelap joint assembly130 and a fastener extending through a compression plate 208, the femalefirst leg portion 136, the male first leg portion 146, the sealant andoptionally, the clip. Item 208A serves as a nut for item 210 and plate208B is optional. Connections may be made by self-drilling andself-tapping fasteners, or with a field drilled hole in the assembledcorrugation and a bolt inserted therethrough.

Assembly may consist of sliding item 208A up inside the corrugation fromthe end of a panel or by sliding item 208A in under the distal end ofitem 160. Optionally, the item 208A may be inserted before the female issnapped over the male. The assembly may occur at an endlap or at anylocation throughout the sidelap.

Sealant under the head of the bold, the compression plate under the headof the bolt or the nut on the other side of the corrugation will havesealant to prevent leaks. The purpose of the assembly is to prevent thecorrugation from opening when subjected to wind uplift.

FIG. 25 shows a sidelap joint assembly 130B, which has the sameconstruction as the sidelap joint assembly 130 shown in FIG. 23, withthe addition of fastener, or compression plates 206B and 208B similar tothose shown and previously described with reference to FIG. 24. As withthe sidelap joint assembly 130A shown in FIG. 24, the sidelap jointassembly 130B in FIG. 25 allows the fastener plate 208B to serve as thenut for the fastener item 210, which may be either a self-drilled,self-tapped fastener, or a bolt used with a pre-drilled hole. Further,assembly may be performed in a similar fashion as that describedhereinabove for FIG. 24.

It has been known for some time that certain forms of panel sidelapstend to unfurl and unzip when subjected to wind uplifts and other forcesthat cause them to deform into loaded shapes similar to that shown inFIG. 9A. When panels containing substantially flat areas are subjectedto uplift loads, the sidelaps tend to separate and the overlappingfemale corrugation rotates in relation to the underlying male. This isthe result of the overlapping female not engaging or gripping theunderlying male sufficiently to prevent unfurling and then unzipping.

External clips, such as BRS Clamp Clip 102 and other similar clips havebeen applied externally to the corrugation in an attempt to prevent suchunfurling and unzipping, but have met with limited success.

When unfurling and unzipping are to be prevented by constructing thefemale so that it does not rotate in relation to the corresponding male,one associated problem is that the female does not grip the male tightlyand offers little rotational restraint to unfurling. This phenomenon isaddressed in the sidelap shown in FIG. 23, wherein it is noted that themoment arm between the rotational points shown should be extended toprevent the top of the female from rotating in relation to the top ofthe male thus allowing the panel sidelap to open between the male andthe female as the flat of the panel bows up and at least a portion ofthe panel flat forms a catenary across the panel.

The proper restraint to prevent or minimize this action may be achievedby shaping the corrugation so rotational resistance between the male andthe female is achieved. Such rotational restraint may be achieved by thefemale and male forming similar equal and opposite counter-actingcouples at those points where the female contacts the male. As unfurlingand unzipping forces act upon the seam, the panels exert forces againsteach other, resulting in the opposite counteracting couples that tend toresist the unfurling and unzipping of the panels. Such couples may beseen in FIGS. 23 and 39.

FIGS. 26-35

Referring now to FIG. 26, shown therein is a schematic side view of astanding seam assembly 500, similar to the sidelock joint assembly 130previously described with reference to FIG. 23, but having certainimprovements over them. In contrast to the previously describedinterlocking seams, however, the seam assembly 500 provides a field rollformed seam between adjacent contiguously placed roof panels 502A and502B wherein a conventional field roll forming tool (not shown) isapplied to form and complete the seam. It should be understood that thepanel, prior to seaming, may be formed in the field or in the factoryand shipped to the field in its formed shape. The seam assembly 500shown in FIG. 26 illustrates roof panels 502 in a condition prior to theapplication of the field roll forming tool, so that FIG. 26 shows abefore-field roll formed configuration.

FIG. 26 provides a first roof panel 502A with a female sidelap joint 504having first and second leg portions 506 and 508, respectively, whichare formed in a direction generally normal to the first roof panel 502Aand separated by a connecting portion 510. A cavity 512 is formedthereby and into which extends a male sidelap joint 514 comprising afirst leg portion 516 formed in a direction extending from the adjacentroof panel 502B. The first leg portion 516 is placed so as to extendadjacently to the female first leg portion 506 as shown. The malesidelap joint 514 further comprises first and second radiused portions518 and 520 as shown and a mastic contact portion 522, extending beyondthe second radiused portion 520. The mastic contact portion 522 contactsa mastic material 524 that is sandwiched between the mastic contactportion 522 and the connecting portion 510 of the female sidelap joint504.

A hold down clip 526 supported by the underlying building structure (notshown) is disposed to interlock over the first radiused portion 518 ofthe male sidelap joint 514. The hold down clip 526 provides a hookingmechanism whereby the seam may be anchored to the underlying buildingstructure. For clarity of illustration, the hold down clip 526 is shownin FIG. 26 to not contact the male sidelap joint 514, but generallycontact will exist between the hold down clip 526 and the first radiusedportion 518 in similar manner as for seams that have been previouslydescribed herein. The hold down clip 526 does not contact the masticmaterial 524 or the connecting portion 510 so that as inwardly directedload causes the panel to settle slightly as tolerances are taken up andas the underlying support material settles slightly, the top portion ofthe clip is free to slide on the first radiused portion 518 easily,allowing relatively lateral movement between the hold down clip 526 andthe first radiused portion 518 without damaging the mastic material 524.

Additionally, FIG. 26 shows an optional horizontal retaining clip 528that provides additional resistance to the "unfurling" or "unzipping" ofthe two roof panels 502A and 502B, as a result of environmental forces.It should be noted that the discussion previously provided hereinabovewith reference to FIGS. 9, 9A, 9B, 10 and 10A in regards to theprevention of unfurling and unzipping are equally applicable to thediscussion and figures presented hereinbelow. Additionally, it will bereadily observed that the horizontal retaining clip 528 is a variant onthe hooking clips 224 and 226 as shown in FIG. 9, in that the horizontalclip 528 provides a one-piece clip and the hooking clip 224 and 226 inFIG. 9 attach to underlying support structure which extends to the nextpanel, so that clip 224 in one panel, clip 226 in an adjacent panel, andthe underlying support structure therebetween are functionallyequivalent to the horizontal clip 528.

The edges of the horizontal retaining clip 528 are formed so as toprovide radiused portions 530 and 532, wherein the radiused portion 530is disposed to contact a corresponding clip surface 534 in the firstroof panel 502A and radiused portion 532 likewise contacts acorresponding clip surface 536 in the roof panel 502B as shown. The clipsurfaces 534 and 536 are sized and spaced so that the horizontalretaining clip 528 may be snapped into place and retained without theneed for securing hardware. The clip surfaces 534 and 536 may beprovided with a generally vertical shape, as shown in FIG. 27, or may beprovided with an S-shape, as shown in FIG. 28. As shown in FIG. 29,which is the view taken along the 29--29 line in FIG. 28, the edges ofthe horizontal retaining clip 528 may be provided with a knurled clipretention surface 538 for providing improved contact between theradiused portions 530, 532 and the clip surfaces 534, 536.

FIG. 30 provides a view of the standing seam assembly 500 aftercompletion of the aforementioned field rolling process. As shown in FIG.30, the second leg portion 508 of the female sidelap joint 504 is rolledso as to generally follow the contours of and be in near proximity tothe male sidelap joint 514. The length of the second leg portion 508 maybe varied, but should be sized so that an end point 540 of the secondleg portion 508 is located far enough down the male first leg portion516 in the direction of the roof panel 502B to prevent unfurling of thecorrugation as it is subjected to upwardly directed load generallyperpendicular to the panel. Locating the end point 540 towards the roofpanel 502B provides additional resistance to the unzipping of the roofpanels 502 by providing a spring force between the end point 540 and thefirst leg portion 516 of the male sidelap joint 514 as the roof panel502B is lifted as a result of the previously described environmentalforces.

FIG. 31 provides an alternative view of the standing seam assembly 500after completion of the field rolling process, in which the second legportion 508 is brought generally at an angle towards the male sidelapjoint 514, instead of generally following the contours of the malesidelap joint 514, as shown in FIG. 30. As with the field roll formedseam shown in FIG. 30, the end point 540 of the second leg portion 508in FIG. 31 is located so as to be sufficiently near the roof panel 502Bat the base of the male sidelap joint 514 so as to prevent unfurling andunzipping of the seam. The second leg portion 508 may be roll formed soas to provide a radiused section 542, an angled section 544 and avertical section 546, the angle and length of the vertical section 546largely determined by the overlap required to prevent seam unfurling andunzipping.

In addition, the corrugation's resistance to unfurling and unzipping maybe further enhanced by the addition of a seat 541 formed into the firstleg portion 516 to prevent the end point 540 from being forced downwardas the panel is subjected to uplift or outwardly directed load thattries to rotate the male in relation to the female and the male andfemale sidelaps attempt to separate one from the other (in other words,the seat 541 acts as a latch). FIG. 31A provides an enlarged view of theseat 541.

Turning now to FIG. 32, shown therein is a schematic side view ofanother field roll formed standing seam assembly 550. As with thestanding seam assembly 500 shown in FIG. 26, it should be understoodthat the seam assembly 550 shown in FIG. 32 illustrates the seam in acondition prior to the application of a conventional field roll formtool, so that FIG. 32 shows a before-roll formed configuration.

FIG. 32 includes roof panels 552, denoted as a second roof panel 552Aand a second roof panel 552B which are brought together as shown duringassembly. The first roof panel 552A comprises a female sidelap joint 554having a first leg portion 556 extending from the first roof panel 552A,a radiused portion 558, a portion 560 that is generally parallel to thedirection of the first roof panel 552A, and finally a second leg portion562 that extends toward the first roof panel 552A at an angle. Thesecond roof panel 552B has a male sidelap joint 564 that is brought intonear proximity with the female sidelap joint 554 as shown.

The male sidelap joint 564 comprises a first leg portion 566 thatextends generally in the direction of the first leg portion 556 of thefemale sidelap joint 554, with the first leg portion 556 connected to aradiused portion 568 that fits within the radiused portion 558. The malesidelap joint 564 further comprises a mastic contact portion 570, thatextends generally in the same direction as the portion 560 and has themastic material 524 attached thereto.

Between the female sidelap joint 554 and the male sidelap joint 564 is ahold down clip 572, which secures the standing seam assembly 550 to anunderlying building structure (not shown) in a manner similar as otherhold down clips previously described hereinabove. The hold down clip 572has a first leg portion 574 juxtaposed between the first leg portions556 and 566, a radiused portion 576 juxtaposed between the radiusedportions 558 and 568, a portion 578 juxtaposed between the horizontalportion 560 and the mastic contact portion 570, and a second leg portion580 juxtaposed adjacent to the second leg portion 562.

The standing seam assembly 550 further comprises the horizontalretaining clip 528 previously described with reference to FIG. 26 andFIG. 30, for providing additional resistance to the disengaging of thetwo roof panels 552A and 552B as a result of environmental forces.Similarly, the male and first roof panels 552A, 552B are provided withclip surfaces for accommodating and securing the horizontal retainingclip 528.

Referring now to FIG. 33, shown therein is a view of the standing seamassembly 550 after completion of the aforementioned field roll formingprocess, after which the second leg portion 580 of the hold down clip572 and the second leg portion 562 of the female sidelap joint 554 areradiused around the end of the mastic contact portion 570 of the malesidelap joint 564. The second leg portion 562 contacts the masticmaterial 524 so as to provide a weathertight seal. The second legportion 580 of the hold down clip 572, however, does not fracture themastic material 524, allowing the roof panels 552 to move relative tothe hold down clip 572 during thermal expansion and contraction withoutdamaging the mastic material 524. Once roll formed, the hold down clip572 thus serves to anchor the roof panels 552 by restricting upwardmovements of both the female and male sidelap joints 554 and 564,respectively.

Turning now to FIG. 34, shown again in an expanded view is the standingseam assembly 500 previously described with reference to FIG. 30. FIG.34, however, more fully illustrates one method for securing the holddown clip 526 to the underlying building structure.

As shown in FIG. 34, the hold down clip 526 is shown to further comprisea flange portion 582 that turns and runs parallel to the first roofpanel 502A. The flange portion 582 contains a hole (not shown) throughwhich a screw 584 extends, securing the flange portion 582 to theunderlying structure, such as a purlin 586. The effect of the screw 584is to secure the hold down clip 526 to the purlin 586 so as to anchorthe hold down clip 526, and thus the standing seam assembly 500, to thebuilding structure in a vertical direction while allowing the roofpanels 502 to expand or contract relative to the hold down clip 526 in asubstantially horizontal, longitudinal direction (i.e., the direction ofthe seam).

Also shown in FIG. 34 is the horizontal retaining clip 528 which securesthe roof panels 502 in a manner described hereinabove. The horizontalretaining clip 528 may compress a layer of thermal insulation 588 at thelocation underneath the standing seam assembly 500 as shown. Aspreviously described, the thermal insulation 588 runs as a compressedlayer between the roof panels 502 and the purlin 586 and serves tothermally insulate the building structure from the roof panels and theoutside environment.

It should be noted that the hold down clip 526 and the horizontalretaining clip 528 independently operate to secure and resistdisengagement of the standing seam assembly 500. FIG. 35, which is aview taken along the line 35--35 in FIG. 34, shows a partial downwardview of the hold down clip 526 and the horizontal retaining clip 528. Asshown in FIG. 35, the horizontal retaining clip 528 may have a generallyrectangular shape with upwardly radiused edges, denoted by the thinlayers of cross section shown at each end. The horizontal retaining clip528 further has a rectangular opening 590 in the center, through whichthe hold down clip 526 and the head of the screw 584 extend. The flangeportion 582 of the hold down clip 526 partially extends under thehorizontal retaining clip 528, as indicated by the broken lines shown inthe figure. The opening 590 in the horizontal retaining clip 528 allowsa certain amount of freedom of placement between the horizontalretaining clip 528 and the hold down clip 526, and further allows eachto operate independently in securing the standing seam assembly 500. Itis important to note that other shapes for the horizontal retaining clip528 may be used to provide the same function as described hereinabove,and the horizontal retaining clip 528 may be located either over anunderlying purlin or between adjacent purlins, as desired.

FIGS. 36 and 37

Turning now to FIG. 36, shown therein is a standing seam assembly 600having an external clip 604 that provides an external clamping forceupon adjacently disposed female and male sidelap joints 606 and 608 ofroof panels 602A and 602B, respectively. The external clip 604 comprisessheet metal formed so as to slidably mount over the female and malesidelap joints 606 and 608.

The female and male sidelap joints 606 and 608 shown in FIG. 36illustrate a conventional seam configuration with the female sidelapjoint 606 having a radiused portion 610 that is field rolled or lockedover a leg portion 612 of the male sidelap joint 608. Mastic material524 provides a weather proof seal between a hold down clip 616, the legportion 612 and a horizontal portion 614 of the female sidelap joint606. Unlike standing seam assemblies described hereinabove, however, thehold down clip 616 of FIG. 36 contacts the mastic material 524.

The geometries of the external clip 604 are chosen so as to provide aclose fit over the outside of the standing seam assembly 600, bringingthe external clip 604 into near proximity with the female and malesidelap joints 606 and 608. The external clip 604 is installed bydriving the external clip 604 over the seam from one end by way of arubber mallet or other suitable instrument. For clarity of illustration,FIG. 37 provides an isometric view of the external clip 604 prior toinstallation on the standing seam assembly 600. Of course, any number ofdifferent configurations of female and male sidelap joints 606 and 608could be used in substitution for the standing seam assembly 600 shownin FIG. 36, including any of the previously described standing seams, inwhich case the geometries of the external clip 604 would becorrespondingly modified to fit over the seam in like fashion.

Additionally, the external clip 604 may contain one or more screws 618installed through the external clip, the female sidelap joint 606, thehold down clip 616 and the male sidelap joint 608 as shown in FIG. 36 tosecure the external clip 604 and provide additional clamping force uponthe standing seam assembly 600.

The length of the external clip 604 may be selected to run in ahorizontal direction from a few inches to the entire length of thestanding seam assembly 600, as desired, although more installation forceand effort may be required as the horizontal length of the external clip604 is increased. In addition, the vertical height of the external clip604 may be varied so that first and second clip leg portions 620 and 622may be made to approach the base of the roof panels 602A and 602B,respectively. It will be apparent to those of skill in the art, however,that greater clamping force will generally be achieved by providing aclamp having a greater vertical height and by locating the screw 618closer to the base of the roof panels 602A and 602B.

FIGS. 38-48

Referring now to FIG. 38, shown therein is another standing seamassembly 650 of the field roll formed variety with FIG. 38 showing thestanding seam assembly 650 in a pre-roll formed configuration, that is,before the field roll forming operation has taken place. The standingseam assembly 650 is shown to include adjacent female and second roofpanels 652A and 652B having raised corrugation sections includinghorizontal portions 654A and 654B, first angled portions 656A and 656B,and second angled portions 658A and 658B, respectively. The raisedcorrugation sections of the first and second roof panels 652A and 652Bprovide additional strength to the finished roof as well as add to theaesthetic value of the roof by providing an architecturally pleasingdesign.

Although the raised corrugation sections of the roof panels 652A and652B shown in FIG. 38 may be used in conjunction with any of thepreviously described standing seam assemblies, the configuration of thestanding seam assembly 650 of FIG. 38 is shown to comprise a femalesidelap joint 660 having a first leg portion 662 extending in adirection normal to the female horizontal portion 654A, a horizontalportion 664 and a second leg portion 666 which includes a mastic contactportion 668 to which a mastic material 524 is attached. The roof panel652B is shown to have a male sidelap joint 670 that has a first legportion 672 running in a direction normal to the male horizontal portion654B, a first radiused portion 674, a second radiused portion 676 and asecond leg portion 678.

A hold down clip 680 extends between and in close proximity to the firstleg portions 662 and 672 and hooks over the first radiused portion 674of the male sidelap joint 670, securing the standing seam assembly 650to the building structure. The hold down clip 680 extends downwardly andhas a seat 682 on which the horizontal portion 654B of the roof panel652B rests, providing support for the roof panel 652B. The supportprovided by the seat 682 is particularly useful when the seam is firstbeing assembled.

The hold down clip 680 is shown in FIG. 38 to continue to extenddownwardly past the seat 682 until reaching the underlying building orroof support structure, such as a purlin 684 as shown. It should benoted that the hold down clip 680, as well as first angled portions 656Aand 656B of the 652A and 652B, respectively, are shown in a broken linefashion, indicating that the actual lengths of these portions may bevaried and should be sized according to the geometric relationshipexisting therebetween. The hold down clip 680 includes a flange 686 thatextends horizontally and provides a surface through which a screw 688 isplaced to secure the hold down clip 680, and thereby the standing seamassembly 650, to the purlin 684. As described previously with referenceto FIG. 34, the flange 686 compresses a layer of thermal insulation 690in the area immediately adjacent to and under the flange 686.

FIG. 39 shows the standing seam assembly 650 after completion of thefield rolling process using a conventional field seamer (not shown).After the field roll forming process, the second leg portion 666 of thefemale sidelap joint 660 is formed so as to be disposed in nearproximity to the male sidelap joint 670, following the contours thereofand sandwiching the mastic material 524 between the mastic contactportion 668 and the second leg portion 678 to provide a weathertightseal. The length of the second leg portion 666 of the female sidelapjoint 660 may be sized so that an end point 692 of the second legportion 666 extends beyond the base of the male sidelap joint 670 andcontinue over the horizontal portion 654B of the roof panel 652B, asshown. The second leg portion 666 may be shortened or lengthened asdesired, even to the extent it extends down first angled portions 656B,but the resistance of the standing seam assembly 650 to disengagement asa result of environmental forces will be improved when the end point 692is located near or beyond the base of the male sidelap joint 670. FIG.40 provides an optional shape for the field roll formed seam whereinsecond leg portion 666N is formed with a hook shaped return as shown.The second leg portion 666N is formed under the second radiused portion676 in such a manner so that, as uplift forces tend to disengage the twopanels, the second leg portion 666N latches under the second radiusedportion 676 and causes the sidelap to become more securely attached.

Referring now to FIG. 41, shown therein is a standing seam assembly 700with adjacent roof panels 702A and 702B, respectively, assembled inaccordance with the present invention. The standing seam assembly 700 ofFIG. 41 is of the interlocking variety, wherein a female and a malesidelap joint 704A and 704B are aligned and snapped into place duringassembly in a manner similar as that described hereinabove. Further, thestanding seam assembly 700 is provided with corrugation sections similarto the standing seam assembly 650 shown in FIG. 38 and FIG. 39,including first horizontal portions 706A and 706B, angled portions 708Aand 708B and second horizontal portions 710A and 710B.

FIG. 41 shows the standing seam assembly 700 after completion of fieldinstallation. The leg portion 704C of the female sidelap joint 704A isformed so as to be disposed in near proximity to the male sidelap joint704B following the contours thereof and sandwiching the mastic material524 at the top or apex 705 of the standing seam assembly 700, as shown,to provide a weathertight seal. While shown at the apex 705, it will beunderstood that the mastic 524 can be disposed at other convenientlocations within the standing seam assembly 700 in the manner describedelsewhere herein for other standing seam assemblies. The leg portion704C of the female sidelap joint 704A extends angularly from the apex705 and is sized so that the edge of the leg portion 704C forms aretaining groove 707, with a portion of the edge extending away from theapex of the standing seam, and the retaining groove 707 opening awayfrom the upstanding portions of the sidelap joints 704A, 704B, or thatis, generally toward the roof panel 702B. The leg portion 704C may beshortened or lengthened as desired so that rollout material of the edgeloops back on itself to extend toward the apex 705, as shown. Theradiused portion 724 of the male sidelap joint 704B extends away fromthe apex 705 to a point within the cavity of the female sidelap joint704A where it is bent back over itself to extend toward the apex 705,there forming a locking tab 725.

In the assembled mode of the standing seam assembly 700, the locking tab725 extends into the retaining groove 707, as shown, in such a mannerthat, as uplift forces tend to disengage and open the standing seamassembly 700, the locking tab 725 (the formed edge of the male sidelapjoint 704B) locks within the retaining groove 707 (the formed edge ofthe female sidelap joint 704A) to keep the sidelap joints 704A and 704Bin engagement. That is, as the panels 702A and 702B are subjected touplift forces, pivoting disengagement is attempted by the separation ofthese members at the apex 705, and as this occurs, the locking tab 725and retaining groove 707 permit some upward flexing of the panels 702A,702B while maintaining the latching integrity of the sidelap joints704A, 704B and closure of the standing seam assembly 700.

As with other standing seam assemblies described hereinabove, thestanding seam assembly 700 is provided with a horizontal clip 712, shownin cut-away fashion in FIG. 41, which secures the roof panels 702A and702B. FIG. 41 shows the horizontal clip 712 in near proximity to andsupported by clip contact surfaces 714 provided within the secondhorizontal portions 710A and 710B. FIG. 42 shows an enlarged view of thehorizontal clip 712 and the clip contact surface 714 for the right sideof the horizontal clip 712. As shown above with reference to FIG. 29, aknurled clip retention surface 716 may be provided at the edge of thehorizontal clip 712 for improved contact between the horizontal clip 712and the clip contact surface 714.

An alternative to the horizontal clip 712, as shown in FIG. 41, isprovided with reference to FIG. 43, which shows a horizontal clip 718located at junctions between the horizontal portions 706A and 706B andthe angled portions 708A and 708B of the roof panels 702A and 702B. Thisalternative placement of the horizontal clip 718 places it at the top ofthe corrugated section, as opposed to the bottom of the corrugatedsection as in FIG. 41. FIG. 44 provides an enlarged view of thehorizontal clip 718, as well as a clip contact surface 720 providedwithin the horizontal portions 706A and 706B. As with the horizontalclip 712 as shown in FIG. 42, the horizontal clip 718 may also beprovided with a knurled clip retention surface 716 for improved contactand retention of the clip.

Returning to FIG. 41, the standing seam assembly 700 is shown to includea hold down clip 722 that hooks over a radiused portion 724 of the malesidelap joint 704B and passes through mastic material 524 that isprovided above the radiused portion 724. The mastic material 524, inproviding a weathertight seal also contacts the hold down clip 722. Ifrelative movement between the hold down clip 722 and the radiusedportion 724 occurs, the sealant dam may be broken. Therefore, to preventrelative movement between the hold down clip 722 and the radiusedportion 724 of the male sidelap joint 704B, a two piece floating cliphas been used. More particularly, the mastic material 524 is providedboth on the interior side of the female sidelap joint 704A and theinterior side of the hold down clip 722, so that once the standing seamassembly 700 is assembled the mastic material 524 is sandwiched ontoboth sides of the hold down clip 722 to provide a weathertight seal.Additionally, as it is contemplated that the hold down clip 722 will notrun the entire length of the standing seam assembly 700, but rather onlybe provided at selected locations along the seam, the mastic material524 provided on the interior side of the female sidelap joint 704A willprovide a weathertight seal between the interior side of the femalesidelap joint 704A and the radiused portion 724 of the male sidelapjoint 704B.

To accommodate expansion and contraction of the roof panels 702A and702B relative to the building structure, a two-piece hold down clipassembly 726 is utilized, which comprises the aforementioned hold downclip 722 as well as a clip base 728 to which the hold down clip 722 isattached. The clip base 728 is shown in FIGS. 41 and 43 and is morefully illustrated with reference to FIG. 45.

Referring to FIG. 41 and to FIG. 45, the clip base 728 is shown tocomprise a C-shaped beam section 730, which supports a hook-shapedsection 732 of the hold down clip 722. More particularly, thehook-shaped section 732 of the hold down clip 722 extends under andaround the C-shaped beam section 730 and is provided with a first tab734 that slidably engages on an interior surface 736 of the C-shapedbeam section 730, as shown. The first tab 734 limits the lateral travelof the hold down clip 722, holding the hold down clip in an essentiallyvertical attitude. Additionally, the hook-shaped section 732 of the holddown clip 722 is provided with a second tab 738 that rests on a topsurface 740 of the C-shaped beam section 730, which serves to supportthe hold down clip 722 and to limit its vertical movement. Thus, thefirst and second tabs 734 and 738 serve to secure the hold down clip 722from movement in the vertical direction, while allowing the hold downclip 722 to move longitudinally as the hook-shaped section 732 slidesalong the C-shaped beam section 730. An enlarged view of this portion ofthe two-piece hold down clip assembly 726 is provided in FIG. 45B.

The clip base 728 is shown to further comprise seats 742, which supportthe horizontal portion 706B of the roof panel 702B. The clip base 728may be formed from a single piece of sheet metal formed as shown so asto include rib sections 744 and embossments 746 to provide additionalstrength and resistance to distortional forces upon the clip base 728.

During installation, the hold down clip 722 should be centered to assurethe full range a movement. This is accomplished by a locking tab 747that is formed in the hold down clip 722 such that an indent in theC-shaped beam section 730 is engaged by the locking tab 747 until thelocking tab 747 is positioned over the male leg of the panel at whichtime the locking tab 747 is pushed away from the C-shaped beam section730, thus freeing the hold down clip 722 to slide along the C-shapedbeam section 730.

The hold down clip 722 further has a lower shelf 723 which is formed toslide under the male side lap joint 704B. The lower shelf 723 is formedan an angle that results in a leading edge 723A of the lower shelf 723having to be deflected by about 15 degrees to slide under the malesidelap joint 704B. The deflection of the lower shelf 723 results in acontinuous force being applied to the lower portion of the male sidelapjoint, thus forcing the radiused portion 724 of the male sidelap joint704B into the mastic material 524 contained under the hold down clip722. This will assure that the male side lap joint 704B will be heldfirmly against the mastic material 524 throughout the life of the roofsystem.

The clip base 728 further comprises an insulation tab 748 useful insecuring a foam block insulation strip (not shown) that may be placedover a layer of thermal insulation 750. The foam insulation strip willbe sized to a width that will fit between the reinforcing seats 742 onthe previously installed clip base and will be of a length that willallow the insulation tab 748 to embed into the opposite end of the foamblock as the clip is being installed, thus capturing both ends of thefoam block. This will hold the foam block in position as the panelsexpand and contract.

The base of the clip base 728 is anchored to the underlying structure,such as a purlin 752 using conventional hardware, such as screws 762shown in FIG. 45A. More particularly, FIG. 45A shows that the clip base728 may be attached to the underlying structure by means of the screws762 through a flange portion 756. To provide a solid connection of thebase over the thermal insulation 750, the flange portion 756 is formedwith feet 758 that extend downwardly at an angle normal to the flangeportion 756 and which easily compress the thermal insulation 750 so asto bear solidly on the purlin 752. The feet 758 are formed by punchingsquare holes 754 through the flange portion 756 and forming opposingsides of the square downward. Additionally, a back edge 757 of theflange portion 756 is formed downwardly to provide a foot surface 764that acts in cooperation with the feet 758 to support the flange portion756.

Finally, returning to the discussion concerning the mastic material 524used to provide a weathertight seal between the hold down clip 722, theinterior side of the female sidelap joint 704A and the radiused portion724 of the male sidelap joint 704B, a notch 760 in each end of the holddown clip 722 is shown in FIG. 45. The notch 760 provides a V-shapedcutaway at the end of the hold down clip 722, beyond which the masticmaterial 524 attached to the interior side of the hold down clip 722extends, as shown. The purpose for the notch 760 is to provide astructure that will carry sufficient mastic material 524 to bridgebetween mastic material 524 carried by the underside of female sidelapjoint 704A and the radiused portion 724 of the male sidelap joint 704Bwhen in the assembled position. That is the mastic material 524 willremain positioned under the notch 760 until the hold down clip 722 ispositioned over the male sidelap joint 704B, at which time the masticmaterial carried by the end or the hold down clip 722 bridging the edgesof the notch 760 will be extruded up, forming a sealant nodule that willeasily join with the mastic material 524 in the female sidelap joint704A.

Turning now to FIG. 46, shown therein is yet another interlockingstanding seam assembly 800, comprising roof panels 802A and 802B,respectively, placed adjacently as shown and locked into place duringassembly. The standing seam assembly 800 includes a female sidelap joint804 having a first leg portion 806, a first radiused portion 808, asecond leg portion 810 and a second radiused portion 812 constructed asshown. A mastic material 524 is provided and attached to the interior ofthe second radiused portion 812. A male sidelap joint 814 is interlockedwith the female sidelap joint 804 and comprises a first leg portion 816,a first radiused portion 818, a second radiused portion 820, and asecond leg portion 822 with a tapered edge 824 at the end of the secondleg portion 822. The second radiused portion 820 contacts and forms aweathertight seal with the mastic material 524 and the tapered edgerests against the interior edge of the first radiused portion of thefemale sidelap joint. A hold down clip 826 is provided that contacts andexerts a downward force upon the first radiused portion 818. The holddown clip 826 has an endpoint 828 that extends towards, but does notcontact the second radiused portion 820 of the male sidelap joint 814.

The hold down clip 826 includes a seat 830 on which the male sidelapjoint 814 may rest either during or after assembly of the standing seamassembly 800 and the hold down clip 826 extends downwardly and issecured to the underlying building structure (not shown) in either aconventional manner or a manner as disclosed hereinabove.

Turning now to FIG. 47, shown therein is a representation of thestanding seam assembly 500, as shown previously with reference to FIG.30, containing both the aforedescribed hold down clip 526 and thehorizontal clip 528 which are used to secure the standing seam assembly500 to the underlying structure. FIG. 47 illustrates a clamping tool 850that is useful during installation of the horizontal clip 528.

The clamping tool comprises a pair of clamping jaws 852 attached at theends of extension arms 854 that are secured together and pivoted about apivot point 856. Lever arms 858 extend beyond the pivot point 856 andhave attached thereto handle sections 860 that, as with conventionalplier-like tools, enable a human user to provide a clamping forcebetween the clamping jaws 852 by exerting an inwardly directed forceupon the handle sections 860.

The clamping jaws 852 are shown in FIG. 48, which illustrates theclamping jaws 852 in a downward view taken along the 48--48 line shownin FIG. 47. The clamping jaws 852 can be seen in FIG. 48 to eachcomprise two clamp sections 862 located at each end of the clampingjaws, the clamp sections 862 serving to apply the clamping force whenthe handle sections 860 are brought together as previously described.

The purpose of the clamping tool 850 is to assist in the installation ofthe horizontal clip 528 by momentarily compressing the roof panels 502Aand 502B, enabling the horizontal clip 528 to be installed as the roofpanels 502A and 502B are compressed and momentarily brought closertogether. Once the horizontal clip is installed, the clamping force fromthe clamping tool 850 is removed, allowing the roof panels 502A and 502Bto substantially return to their previous relative positions.

The clamping tool 850 is formed from any suitable material sufficient toexert the necessary force upon the standing seam assembly 500 withoutdeformation of the clamping tool 850. Those of skill in the art willrecognize that the geometries of the clamping tool 850 will be dictatedby the geometry of the standing seam assembly 500 and the material usedin the clamping tool 850. Further, it will be recognized that,generally, the clamping jaws 852 may be of almost any length, butoptimally should be chosen to be somewhat longer than the length of thehorizontal clip 528 being installed thereby.

It is clear that the present invention is well adapted to carry out theobjects and to attain the ends and advantages mentioned as well as thoseinherent therein. While presently preferred embodiments of the inventionhave been described for purposes of this disclosure, numerous changesmay be made which will readily suggest themselves to those skilled inthe art and which are encompassed within the spirit of the inventiondisclosed and as defined in the appended claims.

What is claimed is:
 1. A standing seam roof assembly in which adjacentroof panels are supported by underlying support structure in overlappingedge relationship to form a standing seam between adjacent roof panels,the standing seam roof assembly comprising;a first roof panel havingfemale sidelap portion means for forming a male insertion cavity,wherein said female sidelap portion means comprises:a first leg portionextending upwardly from the first roof panel; a first radiused portionextending upwardly from the first leg portion; a second leg portionextending downwardly from the first radiused portion; and a secondradiused portion extending from the second leg portion in a directiontowards the first roof panel, a distal end of the second radiusedportion forming a retaining groove, the male insertion cavity formedthereby, a second roof panel having male sidelap portion means forforming a standing seam assembly, wherein the male sidelap portion meanscomprises:a third leg portion extending upwardly from the second roofpanel; a third radiused portion extending from the third leg portion;and a fourth radiused portion extending from the third radiused portion,and an upward leg portion extending upwardly from the fourth radiusedportion having a distal end receivingly disposed in the retaininggroove; andwherein the male sidelap portion means is inserted into themale insertion cavity to form a standing seam joining the first andsecond roof panels, the standing seam characterized as forming forcecouples that resist forces due to uplift of the first and second panelsso that unfurling of the standing seam between the first and second roofpanels is prevented thereby.
 2. The standing seam roof assembly of claim1, wherein the second radiused portion of the female sidelap portionmeans includes a top surface to which mastic material is attached. 3.The standing seam roof assembly of claim 2, wherein the standing seamassembly is formed by inserting the male sidelap portion means into themale insertion cavity, and forming the standing seam assembly throughelastic deformation of the male and female sidelap portion means,whereby the third radiused portion of the male sidelap portion meansextends over the distal end of the second radiused portion of the femalesidelap portion means, the fourth radiused portion of the male sidelapportion means contacts the mastic material, and the upward leg portionextends upwardly so that a distal end of the upward leg portion is innear proximity to an inside surface of the first radiused portion of thefemale sidelap portion means.
 4. The standing seam roof assembly ofclaim 3, wherein the distal end of the upward leg portion of the malesidelap portion means exerts a spring force upon the inside surface ofthe first radiused portion of the female sidelap portion means when anuplift force is exerted on at least one of the first and second roofpanels.
 5. A standing seam roof assembly in which adjacent roof panelsare supported by underlying support structure in overlapping edgerelationship to form a standing seam between adjacent roof panels, thestanding seam roof assembly comprising:a first roof panel having afemale sidelap portion along one side edge and having a medial portion;a second roof panel having a male sidelap portion along one side edgeand having a medial portion, the female sidelap portion and the malesidelap portion of the first roof panel and the second roof panel,respectively, interconnecting at the lapped together side edges to formthe standing seam, the side edge of the female sidelap portion forming aretainer groove and the side edge of the male sidelap portion forming alocking tab, wherein the retainer groove opens toward the second roofpanel and away from the apex of the interconnected first sidelap portionand the second sidelap portion, the locking tab engaged in the retaininggroove so that unfurling of the standing seam is prevented during whenuplift forces are exerted on the first and second panels; and clip meansfor securing the male sidelap portion of the first roof panel to theunderlying support structure.
 6. The standing seam roof assembly ofclaim 5 wherein the clip means accommodates expansion and contraction ofthe first and second roof panels, and wherein the clip means comprises:aclip base having a beam section; and a hold down clip member slidablyattached to the clip base, the hold down clip member having ahook-shaped section attached to the beam section of the clip base. 7.The standing seam roof assembly of claim 6 wherein the beam section isC-shaped and includes an interior surface, and wherein the hold downclip member extends under and around the C-shaped beam section andincludes a first tab that slidably engages the interior surface of theC-shaped beam section.
 8. The standing seam roof assembly of claim 7wherein the C-shaped beam section further has a top surface and whereinthe hook-shaped section of the hold down clip member further has asecond tab that rests on the top surface of the C-shaped beam section,thereby supporting the hold down clip member and limiting the verticalmovement thereof.
 9. The standing seam roof assembly of claim 8 whereinthe second roof panel has a horizontal portion and wherein the clip basefurther comprises a seat for supporting the horizontal portion of theroof panel.
 10. The standing seam roof assembly of claim 9 wherein theclip means further comprises:centering means for centering the hold downclip member on the C-shaped beam section prior to connection to the malesidelap portion of the second roof panel.
 11. The standing seam roofassembly of claim 10 wherein the centering means comprises:a locking tabsupported by the hold-down clip member; and detent means on the C-shapedbeam section for engaging the locking tab in a tab engaging mode of thelocking tab, the detent means releasing the locking tab when the lockingtab is positioned in a tab release mode when the hold-down clip memberis connected to the male sidelap portion of the second roof panel. 12.The standing seam roof assembly of claim 5 further comprising:sleevemeans for resisting forces due to uplift of the first and second panelscomprising at least one sleeve member generally conforming to theexternal profile of the standing seam and slidable thereover anddimensioned to be secured thereupon.
 13. The standing seam roof assemblyof claim 5 wherein the clip means comprises:horizontal clip means forproviding a retaining force upon at least one of the first and secondroof panels to thereby prevent the unfurling of the standing seam froman uplift force.
 14. The standing seam roof assembly of claim 13 whereinthe corrugated medial portion of the roof panel has a first clipretaining surface and a second clip retaining surface, and wherein thehorizontal clip means comprises:at least one horizontal clip comprisinga C-shaped member having a central web portion, a first radiused portionand a second radiused portion, the first radiused portion including afirst end surface at a distal end of the first radiused portion thatcontacts the first clip retaining surface of the corrugated medialportion of the roof panel and the second radiused portion including asecond end surface at a distal end of the second radiused portion thatcontacts the second clip retaining surface of the corrugated medialportion of the roof panel.
 15. The standing seam roof assembly of claim5 further comprising:means for securing the medial portions of at leastone of the first and second roof panels to the underlying supportstructure so that the standing seam is prevented from unfurling duringuplift forces thereon.